HGV Roadworthiness Checks: Staying Compliant Under DVSA’s 2025 Standards

Introduction

Keeping a heavy goods vehicle in a roadworthy condition is a legal duty for both operators and drivers. The Driver and Vehicle Standards Agency (DVSA) updated its guidance in 2025 to place even greater emphasis on structured maintenance and safety inspections. Every HGV must meet these expectations to operate legally and safely on UK roads. Regular inspections, accurate record keeping, and driver awareness all play a vital part in maintaining compliance and preventing serious defects.

What Does Roadworthiness Mean for HGVs?

Roadworthiness means a vehicle is safe for use on public roads without risk to the driver, passengers, or other road users. The DVSA defines a roadworthy HGV as maintained correctly, structurally sound, and free from defects that could affect safety or performance. It should have fully functional systems including brakes, tyres, suspension, steering, and lights.

The DVSA’s Definition of a Roadworthy Vehicle

Under the updated Guide to Maintaining Roadworthiness, operators are expected to show that their vehicles are inspected at appropriate intervals and that any faults are repaired without delay. The 2025 update reiterates the need for evidence-based inspection frequencies and confirms that electronic maintenance records are acceptable if they contain all required information. Failure to demonstrate compliance can lead to enforcement action, prohibition notices, or loss of an operator licence.

Legal Requirements and Operator Responsibilities

Every HGV operator has a duty under the Road Traffic Act 1988 and the Goods Vehicles (Licensing of Operators) Act 1995 to ensure that vehicles are safe and roadworthy at all times. This responsibility extends beyond the annual MOT and includes daily checks and planned safety inspections. Using, causing, or permitting the use of a vehicle in a dangerous condition is an offence under UK law. Operator licence holders must also have suitable facilities and arrangements to keep vehicles fit and serviceable.

Understanding the Guide to Maintaining Roadworthiness (2025 Update)

The 2025 edition of the DVSA guide confirms that operators must carry out a brake performance assessment at every safety inspection, using one of three approved methods:

• Roller Brake Tester (RBT)
• Electronic Brake Performance Monitoring System (EBPMS)
• Decelerometer test with brake temperatures recorded

These requirements are part of the wider move to standardise inspection quality and ensure all maintenance activity is properly recorded. For brake performance assessments and annual brake tests, vehicles must be presented appropriately laden or tested using DVSA-approved load-simulation rollers where applicable.

The Role of Daily and Safety Inspections

Drivers are the first line of defence against defects. A daily walk-around check must be completed before each journey, with any issues reported and repaired. Safety inspections should be scheduled at intervals set by the operator, typically every 4 to 13 weeks, depending on the vehicle’s age, use, and mileage. These intervals should be reviewed and adjusted where necessary to match operational conditions. Checks should cover brakes, suspension, steering, tyres, lights, mirrors, and load security. Refresher courses such as CPC Training help drivers recognise early warning signs and understand how to report them correctly.

Key Areas Covered in HGV Roadworthiness Checks

A full roadworthiness inspection examines mechanical and structural elements to confirm that the vehicle performs as designed under normal operating conditions.

Brakes, Tyres, and Suspension

The braking system must meet DVSA efficiency standards with no air leaks or pressure loss. Tyres should have sufficient tread depth and show no cuts, bulges, or uneven wear. Suspension systems need careful inspection for air leaks, damaged bushes, or broken springs. Poor suspension affects braking balance, steering control, and load stability, leading to increased wear or MOT failure. Drivers who complete HGV Training learn how these systems work together to maintain stability and road safety.

Steering, Lights, and Load Security

Steering mechanisms should operate smoothly without stiffness or excessive free play. Lights and reflectors must be clean, correctly aligned, and fully functional. Load security is a legal requirement and forms part of roadworthiness checks. The DVSA can issue immediate prohibitions for unsafe or unstable loads. Training such as Hiab Training helps drivers understand safe loading, weight distribution, and how these factors influence braking and steering.

DVSA Compliance and Record Keeping

Accurate maintenance records are essential for proving compliance. Operators must keep documentation for all inspections, repairs, and brake tests. The DVSA encourages electronic record systems as they make it easier to track maintenance history and demonstrate compliance. Records should include:

• Dates and signatures for each inspection
• Details of repairs, retests, and replaced parts
• Calibration certificates for test equipment
• Any risk assessments used for load simulation or exemptions

Inspectors may request these records during an audit or roadside investigation. Missing or incomplete documentation can result in warnings, prohibitions, or prosecution.

Maintaining Inspection Records and Evidence

A well-structured maintenance system links inspection reports to each vehicle and tracks repairs from defect report to completion. Operators using digital management tools can more easily analyse trends and identify recurring faults. Regular internal reviews help improve MOT pass rates and maintain a positive Operator Compliance Risk Score (OCRS).

Supporting Roadworthiness Through Training

Ongoing training remains one of the most effective ways to maintain compliance. Understanding how each vehicle system functions helps drivers and maintenance staff prevent minor faults from escalating into serious safety issues.

Courses such as CPC Training focus on the legal importance of daily walkaround checks and accurate reporting. Likewise, HGV courses provide the technical knowledge needed to identify worn or failing components. Together, they promote a culture of safety and responsibility across the transport industry.

CPC and Operator Awareness Courses

Management-level training helps operators plan inspection schedules, maintain compliance records, and prepare for DVSA audits. Awareness programmes also reinforce the importance of proactive defect management. A well-trained workforce reduces downtime, lowers maintenance costs, and helps operators meet the latest DVSA standards.

Summary

Roadworthiness sits at the heart of vehicle safety and legal compliance. The DVSA’s 2025 standards emphasise planned inspections, reliable record keeping, and the need for trained personnel who understand their obligations. By combining daily driver checks with structured maintenance and brake performance assessments, operators can stay compliant, protect their licences, and keep UK roads safe for all users.