How Equipment is Truly Tested
When it comes to fitness equipment, appearances can be deceiving. Sleek lines and polished materials are one thing—but for facility managers who need machines that endure daily abuse, reliability is non-negotiable. That’s where durability testing comes in.
We sat down with Todd Graham, Senior Manager of Hardware Validation & Reliability Engineering at Life Fitness / Hammer Strength, to get a behind-the-scenes look at how top-tier commercial fitness equipment is put through the wringer before it ever reaches your facility floor. If you’re a facility operator or manager, this is your crash course on how to assess equipment durability—and why it should matter to your bottom line.
Q: Why is durability testing so critical for fitness facilities?
Todd Graham: Equipment in commercial gyms operates under relentless conditions. Unlike consumer gear, our products are used for hours every day by hundreds of users of different sizes and intensities. Durability testing allows us to simulate those conditions in a compressed timeframe so we can find and fix weaknesses before our customers ever see them.
Put simply: we test and break our machines so yours don’t break later.
Q: What kinds of testing does your team perform?
We run three major categories of testing:
- Mechanical Testing – Assessing strength, wear, and fatigue at the component, subsystem, and full-system levels.
- Electrical Testing – Includes power cycling, compliance with safety standards, and surge tolerance.
- Environmental Testing – Simulating real-world extremes like high humidity, heat, cold, and salt fog to assess corrosion resistance and performance under stress.
Q: What’s the difference between standard and custom mechanical testing?
Standard testing follows industry protocols—like ASTM and IEC—for things like compliance, safety, and baseline durability.
Custom testing is where we take things further. Every new product has unique stress points and user interactions. We design specific loading and performance scenarios based on real-world use. This often means building custom rigs, instrumenting parts with sensors, and gathering data from testers of different weights and statures.
Q: Can you walk us through what custom mechanical load testing looks like?
Absolutely. When we’re developing a new product:
- We instrument key components with strain gauges—sensors that measure stress on parts during use.
- Then we run machines through controlled use cases with test subjects of various sizes or robotic actuators simulating thousands of reps.
- The data tells us where loads are higher than expected, or where materials might fatigue over time.
A great example is the Symbio™ Incline Elliptical. During testing, we identified fatigue failures in the crank and rocker arms. We redesigned those parts, retested, and confirmed the updated design could handle commercial use without issue.
Q: What’s cycle testing, and why is it important?
Cycle testing exposes components to repeated motion and load over extended durations. Think of it like “fast-forwarding” wear and tear. This shows how parts will hold up to years of use—and helps us redesign anything that starts to degrade too early.
Q: And what about environmental testing?
Environmental testing subjects machines to extreme conditions:
- Salt fog for corrosion testing—great for coastal gyms or facilities with sweat-heavy environments.
- Heat and humidity to mimic unconditioned gyms or shipping conditions.
- Cold storage to simulate transit and warehouse conditions.
It’s all about making sure machines perform and survive, regardless of geography or handling.
Q: What is tip testing, and is it a legal requirement?
Tip testing checks whether a machine could accidentally fall over during use. We analyze the center of gravity and apply load angles to ensure stability. This is especially important for standalone strength machines or when users lean heavily during workouts. It's a compliance and safety requirement in many markets.
Q: How do these tests benefit facility operators directly?
Durability testing leads to:
- Fewer breakdowns and downtime
- Lower service costs
- Stronger ROI through extended lifespan
- Better safety and liability assurance
Facilities can’t afford machines out of order—or users getting hurt. Our testing ensures you're buying equipment that holds up in the real world, not just on a spec sheet.
Q: What certifications back up Life Fitness / Hammer Strength’s testing and manufacturing?
We adhere to major global certifications:
- ISO 9001 – Quality Management Systems
- ISO 14001 – Environmental Management Systems
- FCC / CE – For electronics compliance in the US and Europe
We also test to ASTM and IEC standards—but often exceed them.
Q: What should facility managers ask when evaluating equipment durability?
Great question. Here’s what to look for or ask any brand:
- What kinds of tests do you perform—mechanical, electrical, environmental?
- Are your protocols aligned with recognized standards like ASTM or IEC?
- Do you do custom testing for high-use commercial environments?
- Can you share real-world testing examples or case studies?
- What certifications does your equipment carry (ISO, FCC, CE, etc.)?
- What’s the warranty, and how do you handle service?
- What’s the typical lifespan of your equipment in high-volume facilities?
If a brand can’t answer these, it’s a red flag. Transparency in testing and validation should be part of every commercial equipment purchase.
Why This Matters
For high-traffic gyms, university rec centers, or boutique studios, equipment reliability is a foundational investment. Downtime kills member trust. Frequent repairs eat into margins. A thorough testing process is what separates lasting performance from flashy disappointment.
At Life Fitness / Hammer Strength, durability isn’t an afterthought—it’s built in from day one.
Ready to outfit your facility with equipment that’s built to last?
Let’s talk about how our reliability-first approach supports your space, your users, and your business.