MIL-STD-810G Method 516.6: Shock Testing
Last reviewed: August 2026
MIL-STD-810G Method 516.6 is the shock test method within MIL-STD-810G, the U.S. Department of Defense test method standard for environmental engineering considerations and laboratory testing.
Method 516.6 is used to evaluate whether equipment can physically and functionally withstand the relatively infrequent, non-repetitive mechanical shocks it may encounter during handling, transportation and operational service. It can also be used to determine equipment fragility, establish packaging requirements and evaluate mounting or restraint systems for crash environments.
For rugged computing systems, shock testing can help identify weaknesses in chassis structures, circuit boards, connectors, storage devices, fasteners, mounting hardware and other components before equipment is deployed into demanding military, aerospace, transportation or industrial environments.
Revision note: MIL-STD-810G Method 516.6 remains relevant because it is still referenced by legacy programs, contracts and equipment specifications. The current revision of the standard is MIL-STD-810H w/Change 1, where shock testing is addressed by Method 516.8.
Quick look at MIL-STD-810G Method 516.6
- Environmental condition: Mechanical shock
- Standard: MIL-STD-810G
- Test method: Method 516.6
- Primary purpose: Evaluate physical integrity and functional performance following or during mechanical shock
- Common applications: Rugged computers, military electronics, vehicle-mounted equipment, avionics, transportable systems and other mission-critical hardware
- Number of procedures: Eight
- Current equivalent: MIL-STD-810H Method 516.8
- Important consideration: Test levels and procedures must be tailored to the equipment’s expected life-cycle environment
What does MIL-STD-810G Method 516.6 test?
Mechanical shock is a short-duration event that can transfer a significant amount of energy into equipment. Examples can include a sudden impact, rough handling, a drop, abrupt vehicle movement or a crash event.
Method 516.6 is intended to determine whether those events could cause physical damage or affect the equipment’s ability to perform its required function.
Potential problems exposed by shock testing may include:
- Circuit board or electronic component damage
- Intermittent or failed electrical connections
- Connector separation
- Cracked solder joints or circuit boards
- Loosened fasteners or internal hardware
- Permanent deformation of structural components
- Failure of equipment mounts or restraints
- Damage to storage devices or removable components
- Interference or contact between internal components
- Cracking of ceramics, epoxies, glass or other brittle materials
- Functional interruptions caused by short-duration mechanical loads
The standard specifically recognizes that shock can affect both the physical integrity and functional performance of equipment.
What is the difference between shock and vibration testing?
Shock and vibration are related, but they represent different environmental stresses.
Shock is generally a sudden, relatively short-duration event. An impact, drop or abrupt deceleration can produce a large amount of energy over a fraction of a second.
Vibration is repetitive or continuous oscillatory motion that can occur over a much longer period. Vehicle movement, aircraft operation, rotating machinery and transportation are common sources of vibration.
Within MIL-STD-810G, Method 516.6 addresses shock, while Method 514.6 addresses vibration.
Testing for both can be important because a rugged computer that withstands long-term vibration is not automatically proven to withstand a severe transient shock, and the reverse is also true.
The eight MIL-STD-810G Method 516.6 shock procedures
Method 516.6 includes eight procedures. The appropriate procedure depends on how the equipment will be transported, handled, mounted and operated during its service life.
Procedure I – Functional Shock
Functional Shock evaluates equipment in its functional configuration and is one of the most relevant procedures for rugged computing hardware.
The objective is to determine whether the equipment can maintain its required physical integrity, continuity and functionality when exposed to shocks representative of those expected during operational service.
For electronic equipment, this is particularly important because a unit may remain physically intact while experiencing a momentary loss of power, data connection or another functional interruption.
Procedure II – Materiel to Be Packaged
Procedure II evaluates the shock resistance of equipment that will require a shipping container or other protective packaging.
The results can be used to establish the minimum level of shock protection that the packaging system must provide.
In MIL-STD-810H Method 516.8, the comparable procedure is identified as Procedure II – Transportation Shock.
Procedure III – Fragility
Fragility testing helps identify the shock level at which an item may experience physical or functional degradation.
This information can be useful when designing protective packaging, shock isolation or mounting systems. It can also identify situations where the equipment itself should be redesigned to withstand a more severe environment.
Procedure IV – Transit Drop
Transit Drop evaluates the ability of equipment to withstand drops associated with transportation, handling or field use.
Depending on the equipment and test plan, the item may be evaluated inside its transit case, combination case or in a configuration representative of field use.
This procedure should not be confused with the entire Method 516 shock requirement. Drop testing is only one of the eight procedures within Method 516.6.
Procedure V – Crash Hazard Shock
Crash Hazard Shock evaluates equipment, mounting hardware and restraint systems that could become hazardous during a vehicle or aircraft crash.
The objective is not simply to determine whether the equipment continues operating. It is also intended to evaluate structural integrity and whether equipment or components could break loose and create an additional hazard.
This procedure can be particularly important for rack-mounted and vehicle-mounted computing equipment.
Procedure VI – Bench Handling
Bench Handling addresses shocks equipment may encounter during servicing, maintenance or routine handling.
Examples can include an item being tipped, dropped or impacted while it is removed from its normal installation and being worked on.
Procedure VII – Pendulum Impact
Pendulum Impact is primarily intended for large shipping containers or packaged equipment for which conventional drop testing may not be practical.
The test evaluates the ability of the container, packaging system and contents to withstand horizontal impacts.
Procedure VIII – Catapult Launch/Arrested Landing
This procedure applies to equipment installed in or on fixed-wing aircraft that experience the unique mechanical loads associated with catapult launches and arrested landings.
Because the shock environment depends heavily on the aircraft, installation location, mounting configuration and other factors, representative field data are especially valuable when defining test conditions.
Why tailoring MIL-STD-810 shock testing matters
One of the most important things to understand about MIL-STD-810 is that it is not a single pass/fail test with one universal set of environmental levels.
MIL-STD-810G specifically states that tailoring is essential. The procedure, acceleration level, shock duration, pulse characteristics, number of events, test axes, equipment configuration and other parameters should be selected based on the expected life-cycle environment of the equipment.
That means two products can both be legitimately tested using Method 516.6 while being subjected to different shock profiles.
When possible, test conditions should be developed from measured data that represent the actual environment. When those data are unavailable, MIL-STD-810 provides additional guidance for establishing suitable laboratory test conditions.
This is why a statement such as “MIL-STD-810 tested” by itself provides relatively little technical information. A meaningful qualification should identify the revision, method, procedure, test levels and equipment configuration involved.
What do 20g, 40g and 11 ms mean in shock testing?
Rugged computer specifications commonly express shock severity using acceleration in g and duration in milliseconds (ms).
A value such as 20g, 11 ms describes a shock event with a specified acceleration magnitude occurring over a very short period. However, acceleration and duration alone do not completely define a shock qualification. Pulse shape, direction, number of shocks, mounting configuration and the equipment’s response to different frequencies can also affect the severity of the test.
MIL-STD-810G Method 516.6 includes guidance for shock response spectrum (SRS) analysis as well as classical shock pulses. It also specifies that testing should be tailored whenever representative environmental data are available.
Certain Crystal Group product specifications, for example, identify testing to MIL-STD-810 Method 516 Procedures I/V at 20g, 11 ms functional shock and 40g, 11 ms crash hazard shock. These figures describe the requirements associated with those specific products or configurations; they should not be interpreted as universal values required for every Method 516 application.
Why shock resistance matters for rugged computers
Commercial computer hardware is typically designed for controlled environments. Rugged computing systems may instead be installed in vehicles, aircraft, mobile command systems, industrial machinery or other platforms where unexpected mechanical loads are unavoidable.
A shock event can place substantial stress on components throughout a computer system, including:
Chassis and structural components. The enclosure and internal framework must remain mechanically stable without excessive deformation.
Circuit boards and electronics. Printed circuit boards, processors, memory, GPUs and other components must remain securely mounted while avoiding damaging flex or impact.
Connectors and cabling. Power, networking and data connections must remain mechanically secure and electrically reliable.
Storage. Drives, removable storage systems and their mounting hardware must withstand the specified mechanical environment.
Rack and vehicle mounting. Rails, brackets, fasteners and attachment points become part of the complete shock-resistant system.
For mission-critical computing, continued operation may be just as important as avoiding visible damage. That is one reason Functional Shock testing can be especially important when evaluating rugged computer hardware.
MIL-STD-810G Method 516.6 vs. MIL-STD-810H Method 516.8
MIL-STD-810G was issued in 2008, with Change 1 incorporated in 2014. MIL-STD-810H superseded MIL-STD-810G, and the currently active DoD record is MIL-STD-810H with Change 1 dated May 18, 2022.
The shock method changed from:
MIL-STD-810G → Method 516.6
to:
MIL-STD-810H → Method 516.8
The fundamental objective remains similar: evaluate equipment against mechanically induced shock environments expected during its service life.
Method 516.8 continues to contain eight procedures covering Functional Shock, Transportation Shock, Fragility, Transit Drop, Crash Hazard Shock, Bench Handling, Pendulum Impact and Catapult Launch/Arrested Landing. The newer revision also includes updated guidance for test definition, measurement, shock response spectrum analysis and data processing.
For a new program, the contract or system requirement should determine which revision applies. Legacy systems may continue to specify MIL-STD-810G Method 516.6 even though a newer version of the standard exists.
Is MIL-STD-810 a certification?
MIL-STD-810 is more accurately described as a test method standard than a universal product certification.
The Department of Defense describes MIL-STD-810 as engineering and laboratory test guidance built around an environmental tailoring process rather than a single design or test specification.
For that reason, buyers and system integrators should look beyond a generic “MIL-STD-810 compliant” claim and determine:
- Which revision was used?
- Which method and procedure were performed?
- What acceleration, duration and shock profile were applied?
- How many shock events were performed and in which directions?
- Was the equipment operating during the test?
- How was the test item mounted and configured?
- What constituted a passing result?
- Is qualification or test documentation available for the specific configuration?
Those details provide a much more useful indication of whether a rugged computer is appropriate for a particular platform or mission.
Crystal Group rugged computing and shock testing
Crystal Group designs and manufactures rugged computing solutions for demanding defense, aerospace, industrial and edge environments where shock, vibration, temperature and other environmental stresses can affect equipment reliability.
Depending on the product and configuration, Crystal Group systems can be designed and tested to applicable MIL-STD-810 environmental requirements, including Method 516 shock testing. Current Crystal Group product documentation includes rugged computing and networking platforms tested to Method 516 Procedures I and V for functional and crash-hazard shock requirements.
Because Crystal Group systems are highly configurable, applicable environmental qualifications can vary by product and configuration. Contact Crystal Group to discuss the exact environmental requirements, mounting conditions and qualification data for your application.
Frequently asked questions about MIL-STD-810 Method 516 shock testing
Is MIL-STD-810G Method 516.6 still current?
No. The current DoD version is MIL-STD-810H with Change 1, and shock testing is covered by Method 516.8. However, MIL-STD-810G Method 516.6 remains important because existing military programs, contracts and legacy equipment specifications may continue to reference it.
Is Method 516.6 just a drop test?
No. Transit Drop is Procedure IV, but Method 516.6 contains eight separate procedures covering several types of mechanical shock environments.
What is Functional Shock testing?
Procedure I – Functional Shock evaluates whether equipment can maintain its physical integrity and required functionality when exposed to mechanical shocks representative of operational service.
Does Method 516.6 require every product to withstand the same number of g’s?
No. MIL-STD-810 relies on environmental tailoring. Required acceleration, duration, pulse characteristics, axes and other test conditions depend on the anticipated application and life-cycle environment.
How many shocks are performed during a MIL-STD-810 shock test?
The number varies by procedure and tailored test requirement. For Method 516.6 functional-type testing, the general guidance can involve multiple shocks in both directions of three orthogonal axes, but the actual requirement should come from the approved test plan and expected service environment.
Does passing a Method 516 shock test mean a product is MIL-STD-810 certified?
Not in the sense of a single universal certification. The useful question is whether the specific product configuration was tested to the applicable revision, method, procedure and tailored environmental levels required for the application.
Need a rugged computing system for a high-shock environment?
Crystal Group engineers rugged servers, embedded computers, networking systems, data storage and other compute platforms for environments where conventional commercial hardware may not provide adequate reliability.
Contact Crystal Group to discuss your platform, shock and vibration requirements, environmental profile and system configuration.
References and Source Documents
- U.S. Department of Defense – MIL-STD-810G, Environmental Engineering Considerations and Laboratory Tests. See Method 516.6, Shock, for the official scope, tailoring guidance, procedures and test methodology.
- Defense Logistics Agency (DLA) ASSIST – MIL-STD-810 Revision History and Current Status. Official DoD source for MIL-STD-810 revision history, including MIL-STD-810G, MIL-STD-810H and Change 1.
- U.S. Department of Defense – MIL-STD-810H, Environmental Engineering Considerations and Laboratory Tests. See Method 516.8, Shock, for the current version of the MIL-STD-810 shock test method.
- Crystal Group Product Specifications and Environmental Qualification Data. Applicable shock test levels, procedures and qualification requirements vary by product and configuration.