Put an end to mysteries and misunderstandings surrounding sectioning by correctly sizing up damage before taking on the repair.
Many inexperienced and misinformed shop and insurance personnel incorrectly believe that just about any rail/panel can be sectioned. In fact, they physically can be, but can they be safely sectioned, is the real question. Since as the repairers, we are responsible for the safety of the repaired vehicle, you should be sure that the agreed upon repair methodology is safe before undertaking the repair.
Often sectioning is chosen as an option, simply because of the cost savings the procedure may offer, without regard to safety. Although cost is certainly a factor, it shouldn't be the major reason to consider the procedure. Certainly sectioning is a viable and safe procedure, provided the repairs are done properly and careful consideration and evaluation have been done up front.
Since there are hundreds of different vehicle makes and models on the road today, it would be nearly impossible to explain specific sectioning procedures on each one. However, there are some constants that hold true in all cases when evaluating the possibility of performing a section replacement procedure on a severely damaged component.
Initially, a determination must be made whether to replace the damaged component entirely, or by sectioning, instead of repairing the component. Basically, can the damaged component be fixed without considering replacement? I firmly believe that repair should always be your first option. Usually, it's less compromising to the structural integrity of a vehicle to pull and repair a component, rather than cut it apart and replace a portion of it. Many factors are involved in making this decision. However, there are several really simple ones that can help you make your decision quickly and easily in most cases. These include the composition of the component(s) in question; the severity and area of damage on the component; and the accessibility of the damage.
Most of these conditions go hand-in-hand, when considering repair methodology. Let's look at the basics of how these factors affect your decision.
The composition of the component
Many modern vehicles are produced with "exotic" materials — boron, hydroformed, quiet steel, high-strength low-alloy (HSLA) steel and aluminum, just to name a few. Only a few years ago, many of these variants did not exist, and steel was just steel — weldable, heatable, malleable — steel.
Today, however, not knowing and understanding the composition of a component on a new vehicle, before attempting a repair or replace operation, can have dramatic consequences. There may be a severely damaged component that needs to be heated and worked out to re-shape it enough to accept the new part. Using heat on an HSLA steel component for example, changes the molecular structure of the steel, causing it to react to impact forces differently than it did when manufactured. This difference could cause airbags to deploy at incorrect rates, or not deploy at all, causing physical harm to the occupants in the event of a future crash.
If the component happens to be aluminum, do you have the proper training and tools to repair the vehicle? Without specialized tools, and the knowledge, simple galvanic corrosion could cause the aluminum structure to literally decompose after your "repairs," severely compromising the structural integrity of the vehicle. Hydroformed and boron steels present additional and different issues.
Always identify the component composition first
This one factor will dramatically affect the way it must be repaired. The best way to do this is to consult the vehicle manufacturer. Nearly every new car manufacturer offers repair manuals that include model-specific repair procedures for frame rail and sheet metal sectioning and replacement. These will identify the composition, and the factory-recommended areas for sectioning these components, or if it is made from a compound that is not repairable. This is the most reliable and accurate source for this type of repair information.
Most new car dealers have access to this repair information, and will provide it to you through their service departments. You can also view some of this information through the OEM Web sites, or even your local library. I would also recommend contacting the vendors you purchase your OEM parts through for this information. They likely will be much more receptive to your information requests than a dealer with whom you have no relationship. Other sources of information are available, like the Automotive Technical Education Group (ATEG) and I-CAR, to name two. Additionally, some of the mechanical estimating programs include these sectioning procedures in their databases, so your local mechanical shop may be able to help provide you with this information as well.
The severity and location of damage on the component
Once a determination has been made regarding composition, the location of the damage must be considered. Is the damage accessible, or is the damage in a crush zone or a convolution in the rail? Is the component torn or punctured, and if so, is the tear weldable? All of these questions must be answered to determine reparability vs. replacement or sectioning. Again, the vehicle manufacturer's guidelines need to be reviewed before making any decision regarding repair vs. replace/sectioning.
All recommended sectioning procedures will show by illustration, and very precise instructions, the exact location where the manufacturer recommends the sectioning be done, if recommended at all. Comparing these recommendations to the actual damage location on the vehicle will help in determining the probability of repairing and sectioning the component. Obviously, if the damage on the part in question was located after the manufacturers' recommended sectioning location, the entire part would need to be replaced, regardless of what it looks like by outward appearance.Always keep in mind that trained engineers, utilizing huge amounts of crash test and metallurgical data, designed the repair procedures outlined by vehicle manufacturers. Deviating from the recommended procedures without the benefit of all the accumulated knowledge that went into creating that recommendation, or designing that particular part, could have catastrophic results. It would be virtually impossible to look at a vehicle and determine if sectioning would be a viable repair option without knowing the recommended sectioning areas and the composition of the component. Keep in mind that we do not have the ability, or the knowledge, to re-engineer a vehicle. Do not guess at these criteria.
Before writing your initial damage appraisal on a vehicle with this type of damage, you should thoroughly research these two areas. Copy the sectioning procedures and keep them in your file as backup regarding your repair procedures and recommended charges on your initial estimate. When and if you are questioned, you will have the answer to any questions regarding viability of the procedure. I don't know of one single insurance company that would agree with an unsafe and improper repair. This documentation is extremely important.
Accessibility of the damage
Once you have determined that the damaged component is a candidate for sectioning by considering the first two criteria, look at the access available to perform the operation. In some instances, nearly all the same components that block access on a sectionable part need to be removed when doing a full replacement. If this is the case, what benefit does opting for sectioning provide? Sometimes it's very little, or none in reality — especially if the determination to section is based solely on visible factors and is not based on recommended procedures.Many times when sectioning, the damaged component has an area that must be repaired to accept the new section. Do you have access inside of a rail, for example, to be able to work out damage sufficiently to install the new component? Can your technician gain access to weld the two components together correctly, with sufficient penetration? Can they apply the correct type of corrosion protection once the welding is completed?
All of these considerations must be addressed prior to beginning the repairs. When doing so, thoroughly look over the vehicle by lifting it in the air for underneath access, as well as overhead. I would also recommend that the damaged vehicle be set up and measured as part of the estimating process. This will help you determine the true severity of the damage, before looking into reparability. You will be able to see if damage exists outside of the sectioning area as well, possibly requiring a full replacement rather than a section if pulling the damage will not restore the factory dimensions. The "before" printout will be needed as part of your repair documentation anyway.Utilizing these simple tools when considering sectioning, along with the OEM repair data, will always lead you to the most logical and safe repair method. Sectioning does not need to be as mysterious and misunderstood as it may be, provided the proper research is done prior to making the decision to perform the operation. No two vehicles are made exactly alike, so even if you sectioned a similar structure in the past, always do the research before jumping in feet first. It's much safer — for all of us.
