Why Brake Testing at Every Safety Inspection Is Critical — And Why Your Vehicle Must Be Loaded
When it comes to vehicle safety, few systems are more vital than your brakes. The DVSA’s Guide to Maintaining Roadworthiness makes it clear: a brake performance assessment must be conducted at every safety inspection. To remain compliant, operators must ensure that vehicles are adequately loaded during these tests — and failing to do so could mean falling short of your legal obligations under your operator licence.
Brake Testing Requirements: What Does the DVSA Say regarding a Brake test at every inspection?
According to the latest DVSA guidance, every safety inspection must include a brake performance assessment, which can be one of the following:
- A roller brake test (RBT)
- A decelerometer test (only acceptable for trailers or if an RBT is not practical)
- An electronic brake performance monitoring system (EBPMS) if approved and validated
The preferred method is a roller brake test, as it provides the most accurate and consistent measurement of brake performance. Critically, these tests must be conducted with the vehicle in a laden condition (normally to at least 65% of its design gross weight) to ensure accurate results that reflect real-world braking conditions.
Why Must Vehicles Be Loaded During Brake Tests?
A loaded vehicle has very different braking dynamics compared to an empty one. Testing brakes in an unladen state often fails to apply enough brake force to simulate operational conditions, potentially hiding serious performance issues. According to the guide:
“Brake testing should be conducted with a laden vehicle to obtain meaningful results — unladen tests may not accurately reflect braking capability under normal working conditions.”
As such, meaningful brake test results can only be obtained when the vehicle is appropriately loaded. The DVSA recommends using ballast loads or scheduling inspections when the vehicle is already carrying cargo, where safe and practical. So you should ensure your maintenance provider carries out a Brake test at every inspection
Evidence and Record Keeping
Brake performance test reports must be retained and made available during roadside checks or DVSA audits. The inspection sheet should include:
- The date and location of the brake test
- The method used (e.g., RBT, decelerometer)
- Results for each axle, including service and parking brakes
- Confirmation that the vehicle was laden
Consistent, properly documented brake testing is one of the best defences against enforcement action, prohibitions, or operator licence reviews.
Avoiding Common Pitfalls
Many operators still conduct safety inspections without a proper brake test, or they run RBTs with unladen vehicles. This can:
- Trigger DVSA enforcement action during fleet audits
- Contribute to poor OCRS scores
- Jeopardise your Operator Licence under Public Inquiry
To comply fully, your system of maintenance must include:
✅ Brake testing at every safety inspection
✅ Use of a roller brake tester where possible
✅ Ensuring the vehicle is properly loaded
✅ Accurate record keeping of test results
Final Thoughts
Brake testing isn’t optional. It’s a core part of your commitment to vehicle safety and roadworthiness. Whether you’re an operator, transport manager, or workshop controller, ensuring a loaded brake test at every inspection is essential to staying compliant and protecting your fleet, drivers, and other road users.
If you’re unsure how to implement effective brake testing within your maintenance system, seek professional advice or training. Your commitment to compliance starts with proper braking.
View the DVSA Guide to maintaining roadworthiness here