Roller Brake Testing

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As is often the case, the issues surrounding roller brake testing has raised its head at several recent public inquiries I’ve attended.

There is available guidance on what is expected in the form of various government publications:

  1. The Guide to Maintaining Roadworthiness
  2. The Heavy vehicle brake test: best practice
  3. Guidance: Understanding your HGV or trailer’s brake test report

Operators must assess brake performance during every safety inspection, in order to comply with legal requirements and maintain roadworthiness.

Brake performance must be assessed at every safety inspection

Operators are expected to assess braking performance during every scheduled inspection using one of the following methods:

Preferred method

  • Laden Roller Brake Test (RBT) – the most accurate method.
  • A test can be carried out up to 14 days before the inspection.
  • The RBT printout must be attached to the maintenance record.

Alternative acceptable methods

Used only when RBT is not practical:

  1. Electronic Brake Performance Monitoring System (EBPMS)
    • Trailer-only technology that monitors braking during use.
    • The data must be evaluated, signed, and stored with the inspection record.
  2. Decelerometer test with brake temperature readings
    • Acceptable for vehicles without trailers or where RBT cannot be used.
    • Requires before/after temperature checks showing consistent heating across axles.

When is EBPMS used

This is only available for trailers and must show:

  • Sufficient braking events
  • Performance values compared to legal standards
  • Clear identification of vehicle/trailer and monitoring period

If EBPMS data is insufficient, a laden RBT is required.

Risk assessments

If a laden roller brake test is not possible, a competent person must complete a Risk Assessment at that inspection (a proforma document is set out in the Guide to Maintaining Roadworthiness).  An unladen RBT should then also be completed.

A Risk assessment must consider:

  • Vehicle type, age, usage, terrain, load type
  • Previous brake test results and component condition
  • Operational patterns

A single risk assessment may be reused for up to 12 months, but only if operating conditions don’t change.

Brake temperature checks (decelerometer method)

  • Must measure brake temperatures on each wheel before and after testing.
  • Post‑test temperatures must:
    • Be higher than the initial reading, and
    • Be consistent across wheels on the same axle.
  • If results are inconsistent → another method must be used.

What are the paperwork requirements?

  • Evidence of any brake test (RBT, decelerometer, EBPMS) must be:
    • Attached to the safety inspection record,
    • Clearly referenced,
    • Signed/verified by a competent person.
  • The DVSA also now expect the information from the RBT printout to be written on the PMI sheet (as well as attaching the printout)

Special cases

Different rules apply to:

  • PCVs – generally require an unladen RBT at every safety inspection, with decelerometer and temperature allowed in some cases.
  • Small trailers ≤3.5t – tested via static tests, drag/gradient tests or road test with temperature checks.
  • Vehicles that can’t be laden safely – may rely on justified risk assessments and alternative tests.

Problems identified with brakes

If a vehicle fails a roller brake test or has in-service brake issues:

  • A laden RBT must be carried out after repairs before the vehicle returns to service.
  • The test report must be kept as evidence.

Interrogating RBT printouts

Operators should be interrogating the information on their RBT printouts.  This should include

  1. Ensuring the DTp number matches the one on the plating certificate
  2. Ensuring the vehicle is adequately loaded for the test (aiming for 65 per cent of design axle weight)
  3. Any imbalances of 25 per cent require further mechanical investigation

Load simulation

From Thursday, 21 August 2025, DVSA has approved load simulation brake rollers for annual testing. As a result, vehicles may not be required to be loaded before being presented for testing.

Conclusion

Operators are advised to complete a laden RBT at every PMI and then interrogate the findings to satisfy themselves the vehicle’s brakes are safe.

Our specialist team can support you with compliance awareness so that you do not get caught out by changes. Contact Jared Dunbar today for help.