Commercial vehicle repair sector at a crossroads

While much of the industry’s focus has centred on the challenges facing passenger vehicle repair, ARC360 2026 dedicated a specialist session to a sector facing many of the same pressures – but often at an even greater level of complexity.

Bringing together representatives from repair, accident management and vehicle manufacturing, the Commercial Vehicle session – held in association with the VBRA – explored the realities of repairing modern trucks and heavy commercial vehicles, the growing influence of ADAS and electrification, and the urgent need for industry-wide standards, training and collaboration.

Chaired by Tom Hudd, Head of the Vehicle Body Repair Association (VBRA) and featuring panellists: Matt Henson, Managing Director, Square 4 Ltd; Jason Mole, Commercial Vehicle Managing Director, Steer Automotive Group Ltd; and Steve Oakley, Technical Manager, Scania UK, the discussion highlighted a sector undergoing significant change.

“Commercial vehicles are evolving faster than ever,” Tom told delegates. “You thought cars were evolving. Commercial vehicles are evolving equally as fast and they had advanced technologies way before cars.”

Those changes are being driven by many of the same factors affecting the wider automotive market, including Advanced Driver Assistance Systems (ADAS), electrification, alternative powertrains and new vehicle construction methods. However, the panel agreed that the commercial vehicle sector faces additional complexity because of vehicle size, operational demands and the critical role these assets play within businesses.

“The reality is the right repairer has never been so important,” Tom said. “But it’s also never been so complex.”

Stakes are high

For fleet operators, the stakes are particularly high. Unlike private motorists, commercial vehicle owners are not simply concerned about repair costs. Every day a vehicle remains off the road represents lost productivity, disrupted operations and additional expense.

“The repairers are under immense pressure to reduce key-to-key times because that asset needs to be on the road, earning hauliers money and customers money,” Tom explained.

That pressure creates a balancing act between speed and quality – a theme that ran throughout the discussion.

Matt argued that communication has become one of the most important tools available to those managing commercial vehicle repairs.

Historically, fleet operators were primarily interested in one question: when will the vehicle be returned? Today, however, growing awareness of compliance requirements, operator licence obligations and vehicle technology means many fleets are taking a far greater interest in how repairs are completed.

“One of my biggest things is early and accurate communication,” Matt explained. “Tell them early enough. It may not be the good news they want to hear, but tell them early enough so they can plan.”

Expectations

Managing expectations has become increasingly important because modern repairs frequently involve processes that simply did not exist a decade ago.

ADAS calibration was repeatedly highlighted as one of the biggest examples. Even routine repairs such as windscreen replacements can now require calibration procedures before a vehicle can safely return to service.

“If it’s had a front-end impact, if it’s had a windscreen or side cameras, anything like that, I always communicate at the earliest opportunity that you’re going to have to have the ADAS reset,” Matt said.

The challenge is compounded by growing vehicle complexity.

According to Steve the technology found within today’s commercial vehicles increasingly mirrors – and in some cases exceeds – that found in passenger cars.

“If they’re not repaired correctly, they simply won’t work,” Steve warned when discussing ADAS systems. “And we see that often.”

Methods and data

Throughout the session, the panel returned repeatedly to the importance of manufacturer repair methods and technical data.

Unlike passenger vehicle repair, where estimating platforms and repair methods are often readily available, commercial vehicle repairers frequently need to access information directly from manufacturers.

Jason who is also Chair of the VBRA Commercial Vehicle division, explained that obtaining the correct information can be one of the biggest barriers to efficient repairs.

“The methods don’t come in a pre-packaged, easily accessible method portal. None of that information is available readily,” he said. “So all that information before you can even start repair needs to come in.”

The consequences of missing that information can be significant.

Jason highlighted examples where seemingly straightforward repairs become substantially more complex once manufacturer procedures are reviewed. In some cases, repairers may need to remove additional structural components or source specialist parts that were not originally identified during assessment.

Body construction

Commercial vehicles also introduce another level of complexity through body construction.

Unlike passenger vehicles, where manufacturers largely control the entire vehicle, commercial vehicles frequently involve independent body builders who install specialist bodies, trailers, tail lifts and ancillary equipment.

As a result, repairs often require coordination between multiple organisations, each with their own parts supply chains, repair methods and lead times.

The discussion also highlighted the unique challenges associated with chassis repair.

Commercial vehicle chassis structures require specialist equipment, specialist knowledge and highly controlled repair techniques.

Jason warned that improper repairs can have severe consequences.

“A lot of people think, right, if we heat that up, we’ll bend that straight,” he said. “But you can get away with it 90% of the time without heat. Yet 75 to 80% of repairers who try and attempt this will put heat on because they think that’s the way forward.”

The result can be catastrophic.

“If you are a commercial repairer and you put heat into a chassis and you overheat it?” Tom asked.

“Put it in the bin,” Jason replied.

Elite standard

Those challenges have helped drive the development of the VBRA’s Elite Truck Standard, which formed another major focus of the session.

Unlike passenger vehicle repair, commercial vehicle repair has historically lacked a recognised technical standard.

Both Matt and Jason argued that this has created inconsistency across the sector and made it difficult for insurers and fleet operators to identify competent repair partners.

“It guarantees the work is done to the right level,” Matt said of the Elite Truck Standard. “It does what it says on the tin.”

The standard introduces structured assessment, auditing and competency requirements designed to provide greater confidence in repair quality and compliance.

Training and development

Closely linked to that discussion was the industry’s growing skills challenge.

The panel highlighted a significant shortage of formal commercial vehicle training pathways, particularly in areas such as panel repair, MET operations and chassis repair.

Jason revealed that many technicians currently acquire their knowledge through practical experience rather than structured training programmes. “They only know from experience,” he explained.

Tom outlined a number of initiatives designed to address this issue, including the development of new qualifications, bodybuilder training pathways and specialist chassis repair certification programmes.

Electrification is creating additional training demands. While commercial vehicle EV adoption remains behind passenger cars, manufacturers are rapidly introducing battery-electric and hydrogen-powered vehicles.

Steve described how Scania is already operating hydrogen fuel-cell pilot vehicles and increasing its EV presence within the UK market.

Importantly, he argued that the technology itself should not be feared.

“I’ve kind of embraced it and I respect it,” he said. “Train your people to respect this technology and you’ll have no problems.”

The future

The session concluded by looking towards the future.

Artificial intelligence, digital diagnostics, remote calibration and greater access to vehicle data are all expected to play a larger role in commercial vehicle repair over the coming years. However, the panel agreed that technology alone will not solve the sector’s challenges.

Instead, success will depend on collaboration between manufacturers, repairers, insurers, fleet operators and industry bodies.

Throughout the discussion, one message remained constant: commercial vehicle repair is no longer simply about repairing damage. It is about restoring increasingly sophisticated vehicles safely, compliantly and efficiently.

As commercial vehicles continue to evolve, ensuring repair capability keeps pace may prove one of the sector’s most important priorities.