Correct loading is one of the most important factors at your annual HGV test. The DVSA requires vehicles to be presented with the right load or simulated load to ensure accurate brake testing and overall roadworthiness assessment.
If your vehicle arrives underloaded or incorrectly loaded, it may fail the test, receive poor brake performance results, or be refused a test altogether. Here’s why loading matters and what operators must do to stay compliant.
Why the DVSA Requires a Proper Load
HGV braking systems are designed to work under real-world operating weights. When a vehicle is empty or too light, the brakes cannot perform as they normally would on the road.
This leads to problems during the MOT test, including:
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Inaccurate brake performance readings
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Poor braking efficiency
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Incorrect weight distribution
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Risk of brake lock-up
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A failed test or refusal
Correct loading ensures the test reflects true operating conditions.
The DVSA Minimum Loading Requirements
For accurate brake testing, the DVSA expects most vehicles to be:
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At least 65% of design axle weight, or
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Loaded to the manufacturer’s recommended test weight
This applies to:
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Articulated units
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Rigid vehicles
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Trailers
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PSVs
If a vehicle arrives significantly underloaded, the test centre may not proceed with the brake test.
What Happens When Vehicles Are Underloaded
Underloaded vehicles often show:
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Low brake efficiency
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Poor balance between axles
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High brake imbalance
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Increased stopping distances
These results can lead to:
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A fail
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A retest fee
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Delays to fleet operations
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A negative impact on your compliance record
Correct loading avoids these problems entirely.
How Incorrect Loading Affects Brake Performance
Brakes rely on weight to generate the friction needed for proper performance. When the vehicle is too light:
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Brakes lock more easily
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Axles do not distribute braking force evenly
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Suspension reacts differently
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Brake testing equipment cannot measure accurately
This gives a false impression of brake safety and makes the test unreliable.
Correct Loading Improves MOT Pass Rates
A properly loaded vehicle performs more consistently during brake tests. Operators who load vehicles correctly achieve:
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Higher MOT pass rates
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Fewer re-tests
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Stronger brake test reports
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Better maintenance planning
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Improved OCRS scores
Consistent loading helps build a solid compliance record.
Acceptable Loading Methods
Operators can load vehicles in several DVSA-approved ways:
1. Real Loads
Using actual goods, pallets, or ballast.
2. Water or Sand Ballast
Often used for tankers or rigid vehicles.
3. Load Simulation Devices
Hydraulic rams or systems fitted to the vehicle to create artificial weight.
4. Testing Station Load Services
Some ATFs offer loading services if arranged in advance.
Whatever method you use, the key is ensuring the vehicle meets DVSA loading thresholds.
Who Is Responsible for Ensuring Proper Loading?
The operator is always responsible.
Even if the test station performs the checks, it is your duty to ensure the vehicle arrives correctly prepared.
Operators must:
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Train drivers on loading requirements
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Provide clear instructions before the MOT
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Check weights using weighbridges where needed
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Confirm load security and distribution
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Keep loading documentation
Failure to do so reflects poor maintenance control.
Load Security Still Applies at the Test
Correct weight alone is not enough. The load must also be secure and safe.
Operators must follow:
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DVSA load security guidance
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EN 12195-1 standards where relevant
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Trailer and load restraint manufacturer advice
Loose or unsafe loads can result in a refused test.
Tips for Preparing Your Vehicle Before the Annual Test
Best Practices:
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Confirm weight at a weighbridge
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Use approved ballast materials
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Check that axle weights meet the minimum requirements
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Train drivers on test preparation
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Review past brake test performance
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Keep loading procedures consistent across the fleet
These steps help prevent brake test failures.
How Blue Flag Transport Consulting Supports Operators
Blue Flag helps operators present their vehicles correctly at MOT tests and improve brake test performance.
Their support includes:
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Reviewing brake test history
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Creating pre-MOT preparation checklists
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Advising on loading and axle distribution
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Training drivers on MOT requirements
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Assessing maintenance planning and inspection records
Their guidance helps operators achieve better MOT results and reduce the risk of prohibitions and enforcement action.
Correct loading is essential for accurate brake testing and a successful annual HGV test. Underloading leads to false readings, failures, and unnecessary delays. Operators who prepare their vehicles properly not only improve MOT pass rates but also strengthen their compliance records.
With expert help from Blue Flag Transport Consulting, you can present vehicles confidently, avoid costly retests, and maintain a strong safety record.
Contact Blue Flag Transport Consulting Today
Need help improving brake test results or preparing for annual vehicle tests? Contact Blue Flag Transport Consulting for expert maintenance and compliance support.
