Truck accidents continue to plague South Africa’s roads and as such, each new safety innovation in the heavy vehicle sector is more than a technical milestone – it’s a step toward saving lives. The latest safety development from Mercedes-Benz Trucks in Germany is a stroke of tech genius. The new battery-electric eActros 600 – although not yet launched in South Africa – has undergone rigorous real-world crash testing, underscoring that electrification and safety can – and must – evolve hand in hand. This will come as sweet news to local companies using the eActros 300 or eActros 400 – both of which were introduced into our market in 2024 – for it shows that the move toward electrification need not compromise safety; in fact, it may set a new benchmark.
The eActros 600 combines efficiency and sustainability with what Mercedes-Benz Trucks calls the highest standards of active and passive safety. Long before its series production, the company’s internal accident research team analysed real-world accident data to guide design measures.
“From the outset, our aim was to make no compromises when it came to vehicle safety,” says Felix Pietler, passive safety developer at Mercedes-Benz Trucks. “With electric drives in particular, it is not only important to ensure passenger protection – measures to protect the immediate surroundings are also crucial.”
A real-world side impact crash test in Neumünster proved the value of this approach. Despite significant collision force, the high-voltage battery system and all electrical components remained intact.
Frank Müller, Head of Accident Research & Passive Safety, states: “The test showed that the mechanical stress was high – but our concept works reliably.”
Built to withstand real-world impact
The reinforced cab and defined energy absorption zones in the front end of the vehicle dissipate impact forces in frontal collision scenarios in a targeted manner via crash-optimised structures.
With regard to side impact scenarios, the latest test confirmed that the high-voltage battery modules remained intact and the housing showed no critical deformations thanks to a frame architecture specially developed for heavy-duty collisions. In addition, airbag systems and seatbelt tensioners are available to increase occupant protection in all vehicle variants.
Prior to the test, simulation-based analyses were carried out and sensors were installed and precisely calibrated; each component was precisely tailored to the test scenario.
“For me personally, the last two to three minutes before the crash are particularly fascinating,” says Christoph Berger from the Passive Safety team, describing the moment just before the test sequence is triggered. “Everything becomes quieter than before, and there is a concentrated tension in the air.” Upon impact, more than a ton of mass collides with the side of the truck at a speed of over 50 km/h.
Electrified and fortified
Mercedes-Benz Trucks designed the high-voltage (HV) system with robust insulation, mechanical protection and fire-resistance measures. Each vehicle not only meets but exceeds current legal standards, with results verified by emergency services after each test. “The results clearly confirm our expectations; there would have been no danger here in practical use,” Müller notes.
Even after series launch, the company continues real-world tests to integrate lessons from field data, aligning with its Vision Zero goal of eliminating road fatalities for both conventional and electric fleets.
The eActros 600 is also equipped with cutting-edge driver assistance systems such as Active Brake Assist 6, Active Sideguard Assist 2, Front Guard Assist and Attention Assist 2 – all designed to prevent incidents before they occur. Its Acoustic Vehicle Alerting System (AVAS) ensures that pedestrians and cyclists can detect the vehicle even in silent electric operation.
Range, reliability and responsibility
The eActros 600 boasts a 600+ kWh LFP battery delivering up to 500 km on a single charge and a projected service life of 1.2 million kilometres over ten years. The truck has already proven itself in the “eActros 600 European Testing Tour 2024” and subsequent Winter Tour 2025, and was crowned International Truck of the Year 2025.
With over 40 variants now available, Mercedes-Benz Trucks continues to expand its battery-electric portfolio, merging long-haul capability with the brand’s renowned durability and safety.
Editor’s comment: For South Africa’s trucking community, where road safety remains a national crisis, such engineering achievements offer a glimmer of hope. The tragedy of truck crashes is one we report on too often – and any technology that keeps drivers, passengers and bystanders safer deserves the industry’s attention. The eActros 600 demonstrates that the move toward electrification need not compromise safety; in fact, it may set a new benchmark.
Mercedes-Benz Trucks’ rigorous crash testing shows what can be achieved when manufacturers take real-world data seriously. If global OEMs can lead with this level of commitment, perhaps our own local fleets will soon see fewer tragedies and more technology-driven triumphs on South Africa’s highways.
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