UNDERSTANDING ROLLER BRAKE TESTING

In April 2025, the DVSA introduced a brake performance assessment as part of every safety inspection. The recommendation from the DVSA to adhere to best practice, operators must now conduct a minimum of four laden roller brake tests (RBTs) per year, including the annual MOT.

The change aims to ensure that braking systems operate correctly and help detect potential problems before they become safety risks.

In August 2025, the DVSA introduced load simulation brake rollers as an alternative to manually loading trailers for roller brake testing. This method simulates the weight of a laden vehicle, meaning vehicles do not need to be physically loaded to the required 65% of their maximum weight.

Key points:

• Vehicles that are currently exempt from laden brake testing remain exempt.

• Using load simulation is optional; operators can continue traditional laden roller brake testing.

• Load simulation offers an alternative for laden roller brake tests (RBTs) that are difficult or costly to load.

With the DVSA's updated brake performance standards, fleets can now choose between the traditional roller brake tests (RBT)

and the more advanced Electronic Brake Performance Monitoring System (EBPMS).

Although roller brake testing (RBT) remains a valid testing method, BPW idem Telematics EBPMS provides the advantage of

continuous monitoring, real-time data, and early fault detection, reducing the need for frequent roller tests and improving overall fleet safety.

This decision is not just about compliance – it affects operational efficiency, safety, and long-term costs. As you consider your options, it's

essential to compare the benefits of each method in terms of operational efficiency, safety, and compliance with the DVSA Guide to Maintaining

Roadworthiness guidelines. Discover how EBPMS can transform your brake performance testing.

Vehicles should be loaded with at least 65% of their maximum axle weight during brake performance assessments. This ensures accurate

and reliable testing of the vehicle’s braking performance.

• In situations where it’s difficult to load the vehicle to 65%, vehicles may be tested with a load as low as 50%, but never below that. 

• A load of at least 50% still enables proper brake engagement and prevents early tyre lockups, ensuring a more accurate assessment of stopping performance.

The DVSA’s Guide to Maintaining Roadworthiness highlights certain situations where conducting a laden roller brake test (RBT) may not be possible

or where extra loading causes significant difficulties. Although this list (below) is not complete, operators must make every reasonable effort to perform

brake testing with the vehicle laden.

• Unladen Tri-axle Semi Trailer (ULTAST): Trailers that primarily operate under normal conditions (more than 70% of the time) at less than 65% of the permitted axle weights.

• Vehicles routinely operating below 65% of their permitted axle weights: For example, car transporters are purpose-built for a specific task.

• ADR vehicles: Only when the load is considered dangerous, and specialist facilities are not available.

• Livestock carriers: Such as those used to transport horses, sheep, cattle, where other means of loading are not possible.

• Noxious load carriers: Vehicles designed to transport waste products (e.g., food, animal or human waste) that cannot be used for another purpose.

• Furniture removal vehicles: Only if they are specifically designed and built as furniture removal vehicles.

• Specialist vehicles operating at 50% or more of permitted axle weight when unladen: This could include fixed plant, mobile libraries, compactor vehicles, and exhibition-type vehicles.

NOTE: ONLY IN EXCEPTIONAL CIRCUMSTANCES WILL THE DVSA CHECK THE PERFORMANCE OF THE BRAKES WHEN THE VEHICLE IS UNLADEN.

Roller brake testing (RBT) continues to be a trusted and widely used method for assessing trailer brake performance. It offers several key benefits that assist

fleets in maintaining compliance and ensuring braking efficiency.

• Axle-specific data: Provides precise brake force readings for each axle, aiding in the detection of imbalances, underperforming components, or system faults.

• Proven Compliance: Aligns with DVSA requirements as outlined in the Guide to Maintaining Roadworthiness, ensuring your fleet adheres to essential safety standards.

• Immediate results: The test provides instant feedback, enabling operators to address issues immediately and avoid potential safety hazards. 

• Established industry standard: A roller brake test (RBT) has been the preferred method for decades, making it a familiar and well-understood process for workshops and fleet operators

Despite its advantages, roller brake testing (RBT) poses several operational challenges that fleets need to address:

• Downtime: Vehicles must be taken off the road for testing, leading to operational disruptions.

• Limited monitoring: A roller brake test (RBT) only provides a snapshot of brake performance at the time of testing.

• Laden testing: Trailers must be loaded to at least 65% of their maximum weight capacity, which can be both costly and impractical.

• Accessibility: Not all fleets have easy access to roller brake test (RBT) facilities. Travelling to a testing centre increases downtime and fuel expenses.

• Increased costs: With the requirement of a minimum of four roller brake tests (RBTs) per year, and some fleets conducting inspections every six weeks, expenses for testing, loading, and travel can quickly add up.