A Look Inside Post-Repair Inspections

"Post-Repair Inspection (PRI)" has become a catchphrase in the collision repair industry over the past three to four years. Although PRIs have been around for decades, this term has grown in prominence in recent times for a variety of reasons. For one, the advanced steels used in late-model vehicle construction are generally unrepairable, yet pressure from insurers, unrealistic cycle times, a lack of technician training, antiquated equipment and/or greed have led to these structural components being repaired. This has resulted in noticeable imperfections.

Almost all collision repair professionals have experienced a poorly repaired vehicle in their shop. In some cases, they were horrified by what was done; in many cases, they were unsure of what to do about it. (Note: We're not giving legal advice in this article. Please check with your lawyer regarding the laws in your state.)

Good and Bad Situations

When a car is poorly repaired by a Direct Repair Program (DRP) facility, a good situation is when the insurer will cover the re-repairs and rectify things quickly. The bad situation is when a non-DRP shop (with no ties to the insurer) repairs the vehicle incorrectly and the insurer says to their customer, "You chose the facility." In this situation, the shop owner will need to hire a lawyer. The whole process could take months or even years. Even then, the vehicle owner may not get paid because the shop could go out of business. You must inform the vehicle owner up front what his or her situation is and what the choices are.

We can break this discussion up into several categories:

Good — DRP Facility Repair

• First party is always good.
• Third party can be even better because there is no contractual agreement, but it must have been repaired at the insurer DRP shop.

Options for settlement:

• The vehicle is repairable and you can come to an agreement with the insurer.
• You and the insurer agree that the vehicle is a total loss.
• You come to an agreement with the shop directly.

When the insurer and/or shop disagree:

• The insured can sue the original repair facility and insurer on first party. On third party, they would add the driver and/or owner of the negligent vehicle.
• Have the vehicle owner pay for the repairs and sign an assignment so that you (as the shop) can sue the insurer and repair facility.

Bad — Non-DRP Facility

A lawsuit against the repair facility is the only way. It may take a long time to get restitution, if ever. This is the worst-case scenario.

This is true for insurer-pay or customer-pay repairs. You chose the shop and the insurer does not have to cover the repairs.

Inspection Types

Collision Repair Inspections (CRIs): This type of inspection is the most common and the least scientific. Generally, the vehicle owner will bring a repaired vehicle to a shop of his or her choice to review the repairs. This is usually from a low-speed cosmetic or minor collision event. In most instances, the re-repair will need only slight adjustment, new clips, extra buffing and polishing or (at worst) a sand and refinish. This may be a free-of-charge service, a customer-paid job or (in some cases) the original repair facility will pay for the re-repairs. The insurance company is generally not involved in these types of cases.

Post-Repair Inspections (PRIs): This type of inspection is generally due to noticeably incorrect repairs and/or drivability and operational issues with the vehicle. This is a very extensive inspection where the following will generally be required:

• Hundreds of photographs
• Three-dimensional measurements
• Paint film thickness measurements
• Some destructive testing (disassembly, sanding or grinding)
• Borescope inspection
• Visual weld inspection

Generally, these inspections will uncover enough evidence to suggest extensive re-repairs.

Quality of Repair Examinations (QREs): This type of inspection is the most scientific and requires extensive knowledge of vehicle repair protocols, vehicle design, metallurgy and engineering principles. An engineer or collision damage analyst (CDA) generally performs QREs. A CDA is usually a collision repair expert who possesses extensive training on repair protocols, engineering principles, welding, structural repair and mathematics. A QRE requires these types of experts because they will need to prove what is wrong, why it is wrong, how it is wrong and why these repairs are required. Oftentimes, the expert will be required to go through a Daubert or Frye hearing. In a body shop situation, it is easy to state what must be done because of this or that. In a court situation, you will be required to have scientific proof. These examinations will require extensive and in-depth evidence, including the following:

• OEM-specific repair protocols and procedures
• Hundreds of photographs (in specific numerical order and location)
• Three-dimensional measurements (with calibration reports)
• Paint film thickness measurements (with calibration reports and measurement analysis)
• Visual weld inspection and measurement
• Destructive testing (disassembly, destruction strength tests of components' welds and bonding)
• Macroscopic and microscopic paint material evaluation
• Borescope inspection

Additionally, the client attorney requires an independent to assist in proving the issues.

Training

To become successful at anything, you will need to train and practice (and obviously fail a few times). Your experience in collision repair is extremely helpful, but you will also need to build your résumé, professionally called a CV (Curriculum Vitae). Here is a list of training you will need to assist in your goal of being a PRI technician:

• Experience as a technician
• Current and ongoing structural repair training/certification from multiple lines (Celette, Car-O-Liner, Chief, CarBench, Global-Jig)
• Current and ongoing welding certifications from companies like ISO and AWS
• Current and ongoing OEM training certifications
• Current and ongoing engineering education
• Current and ongoing professional association membership
• Peer-reviewed articles
• Speaking engagements
• Training engagements

This will not happen overnight. It takes time to build your knowledge, experience and recognition in this field. One thing to remember is not to make such a big mistake that it ruins your career. Everyone makes a mistake or two, but don't be so off base that it could prevent you from ever being hired again. Always remember that we are a small community and news travels fast. If you want to get involved in becoming a PRI technician or rising up the ladder to a CDA, take it slow and study. Practice makes perfect. You will need to be proficient at photography, documentation, measuring and note-taking. All of these things will be used in the expert report you will need to write.

PRIs will grow in prevalence as more and more vehicles with advanced high-strength steel (AHSS) or aluminum are produced. This will all be due to many collision repairers' refusal to invest in proper equipment and training, which is causing the current crop of incorrectly repaired vehicles. PRIs are exposing the main issues in our industry, but they cannot address the solutions to ensure safe and proper repairs. Training, education and adhering to standard operating procedures (SOPs) are some things to start with to ensure that proper repairs are being performed. What you do today can destroy what you build tomorrow.

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Larry Montanez III, CDA is co-owner of P&L Consultants with Peter Pratti, Jr. P&L Consultants works with collision repair shops on estimating, production and proper repair procedures. P&L conducts repair workshops on MIG & resistance welding, measuring for estimating and advanced estimating skills. P&L also conducts investigations for insurers and repair shops for improper repairs, collision repairability and estimating issues. P&L can be reached by contacting Larry at (718) 891-4018 (office), (917) 860–3588 (cell), (718) 646–2733 (fax) or via email at larrygoju@aol.com. The P&L website is www.PnLEstimology.com.

Jeff Lange, PE is president of Lange Technical Services, Ltd. of Deer Park, NY (www.LangeTech.net). Jeff is a Licensed New York State Professional Engineer who specializes in investigating vehicle and component failures. Lange Technical Services, Ltd. is an investigative engineering firm performing forensic vehicle examinations and analysis for accident reconstruction, products liability and insurance issues. Jeff can be reached at (631) 667-6128 or by email at Jeff.Lange@LangeTech.net.