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This paper uses NASS/CDS 1997-2004 to determine the crash factors that are most frequently associated with rollover fires. Rollover fire cases were analyzed by the NASS variables including vehicle type, fire origin, number of quarter-turns, and final rest position. Results show that the engine compartment was the most frequent location for the fire origin. The fuel tank was second in this category. The rest position on the roof was most frequently associated with fires in rollovers. However, the fire rate was not strongly influenced by the final rest position. High severity rollovers that involve more than eight quarter-turns or end-over-end motion had fire rates much higher than the average. An examination of 24 cases with major fires in recent model year vehicles found that impacts prior to the rollover occurred in more than half of the cases. All of the cases with leakage from the fuel tank had impacts prior to the rollover.

Seventeen full-scale crash tests were conducted to evaluate technologies to reduce the vulnerability of sidesaddle tanks on full size GM pickup trucks manufactured during the period 1973-1987. These vehicles were alleged by the U.S. Department of Transportation to be vulnerable in severe side impacts. The test program was intended to evaluate designs that would reduce vulnerability in all crash directions. The best test results were obtained by two strategies that relocated the tank to less vulnerable locations. The two locations were: (1) in the cargo bed (bed mounted tank) and (2) underneath the bed, ahead of the rear axle and between the frame rails (center-mounted tank). Tanks mounted in these locations were subjected to a series of crash tests that simulated severe front, side, rear and rollover crashes. The crash environment for these tests was more severe than required by FMVSS 301 “Fuel System Integrity”.