Overload Protection: Safeguarding Fleets and Reducing Risk on the Road

Every day, millions of commercial trucks and vans crisscross European roads, transporting essential goods. However, hidden within this vital network lies a significant risk – overloaded vehicles. This article explains why overload protection is indispensable, looking at the real-world impact, and how VPG Onboard Weighing can bring benefits to everyone in the value chain.

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The very real dangers of overloading

Overloading is not just about exceeding a vehicle’s maximum rated load weight, but also about improper balancing of load across the axles.?

Imagine driving a vehicle loaded beyond its capacity. The steering feels off, the brakes respond sluggishly, and the vehicle struggles to maintain stability. Yet, overloading is all-too common. A survey conducted by the Conference of European Directors of Roads (CEDR) found that, depending on the country, about 2% to 18% of commercial vehicles in Europe are overloaded.?

The key issue is that overloading and unbalanced loading significantly increase the risk of accidents, such as rollovers and rear-end collisions, by impairing vehicle control and increasing stopping distances. According to a report by the European Commission, load-related factors are a significant contributor to accidents involving commercial vehicles.

?A notable example is a truck in France carrying 200% of the maximum allowed load, creating a total weight of 50 tonnes. When the truck went over a bridge with a maximum load capacity of 19 tonnes, the bridge collapsed, and two people died.

The hidden costs of ignoring load limits

The repercussions of overloading extend beyond safety. Overloaded and imbalanced vehicles suffer from accelerated wear and tear, leading to frequent and costly maintenance. Components such as brakes, tires, and suspension are subjected to excessive stress, reducing their lifespan and increasing the related operational costs.

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What’s more, the financial and legal liability implications of non-compliance with load regulations can be severe, both for fleet operators and drivers. Reflecting an increased focus on road safety and compliance, overload fines and penalties on the rise in Europe, albeit with uneven enforcement. In the UK, France and Italy, vehicle weights are checked by authorities relatively frequently, but in some other countries enforcement is laxer. That said, as a result of updates to EU legislation that took effect in May 2024, overload regulations will start being more rigorously enforced in many more countries.

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More hidden costs: fuel consumption and underloading

Overloading a vehicle also significantly increases fuel consumption. Heavier loads require more energy to move, which means that overloaded vehicles consume more fuel. This not only increases operational costs but also results in higher emissions.

?The flip side of the overloading issue is underloading, which may be intentional, in order to leave a “safe margin” of capacity, or simply because the driver is unaware that additional load can be safely transported.

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Weighbridges are not enough

While weighbridges play an essential role in monitoring vehicle weight, they have inherent limitations as they are stationary and can only provide weight information at specific locations. There is no way for the driver to check the weight while loading the vehicle. Weighbridges, or even stationary scales at loading depots also cannot provide information if there are any changes while the vehicle in on route, such as pickups and partial unloading along the way or uneven distribution caused by cargo shifting.

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Technological solutions for overload protection

Onboard weighing solutions, which are installed on the vehicle, offer the best approach to mitigate these risks, protecting operators and drivers from the safety, compliance, and maintenance dangers of overloading.?

At the same time, onboard weighing supports load optimization. Drivers can load trucks and vans close to or at full capacity, enabling more cargo to be safely transported in fewer trips, saving time and fuel.

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VPG OnBoard Weighing: leading the way in overload protection

VPG OnBoard Weighing is at the forefront of providing innovative solutions to combat the challenges of overloading, setting a new level of safety for commercial goods vehicles. Our TruckWeigh? and VanWeigh? systems offer precise, continuous monitoring of load weights directly from the vehicle. ?

• Accuracy and reliability: Our systems provide highly accurate weight measurements, with an accuracy better than ±2.5% at 90-100% of the vehicle's Gross Vehicle Weight (GVW).
• Proven solution: With over 50,000 systems installed worldwide, including in Italy, France, the Netherlands, the UK, the USA, and Australia, VPG's solutions have proven their reliability and effectiveness.
• Integration and ease of use: These systems seamlessly integrate with telematics, allowing fleet managers to monitor loads in real-time and receive alerts for any overload situations. This supports proactive fleet management and enhances operational efficiency.

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Ramping up overload protection in Germany

VPG’s solutions are already in use at a few German fleets, and we are now expanding availability across Germany to help more fleet operators improve safety on Germany’s roads, optimize their operations and reduce exposure to fines for overloading. This is particularly timely, given that we are expecting to see more enforcement in Germany of vehicle weight regulations following the May 2024 update to the EU_219/1213 regulation.

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Conclusion

Overload protection is first and foremost a safety issue. But it is also a critical component of effective fleet management that ensures liability and financial risks, reduces costs, and enhances operational efficiency. VPG OnBoard Weighing’s TruckWeigh and VanWeigh systems offer reliable, accurate, and easy-to-use solutions for fleet managers worldwide. As we expand our presence in Germany, we look forward to helping more fleets operate safely and efficiently.

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For more information on how VPG OnBoard Weighing can support your fleet, visit www.vpgonboard.com or contact me, Christoph Naues, directly.

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About the author:

Christoph Naues, Sales Manager for Germany and Austria at VPG Onboard Weighing, has more than 30 years of experience working in the German automotive market, including with leading manufacturers of vehicles and vehicle safety systems.

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