From April 2025, the DVSA introduced new guidance on HGV brake testing. While the specific requirements depend on individual circumstances, the DVSA’s best practice recommendation is for operators to conduct four laden roller brake tests per year, with vehicles tested at 65% of their design axle weight.

As we approach the first full year under these expectations, many operators are finding that their brake testing equipment is experiencing more wear and tear, leading to patches of missing grit on the rollers.   If the DVSA pays a visit to your garage you will be advised that you must rectify worn rollers, because if your rollers are showing signs of wear or reduced grip, they may no longer meet the standard required for accurate laden brake testing.

Why Operators Are Taking Action

• Increased focus on laden testing puts greater demand on roller condition
• DVSA guidance explicitly emphasises roller grip and condition
• Worn rollers compromise accuracy under loaded test conditions
• Re-gritting prevents costly equipment replacement
• Many workshops are planning maintenance now to stay ahead of compliance issues

If your brake testing equipment is used frequently, showing signs of wear, or providing inconsistent results, now is the right time to ensure continued compliance.

We support fleets, independent workshops, dealerships, and test centres nationwide.

What are my options if my roller coating has failed ?

Replace Rollers with new Rollers form the Manufacturer: This can be very costly – for example new replacement rollers for HGV type Brake Testers can cost £1500 to £2000 per roller.

Re-grit to OEM standards with Porcher Abrasive Coatings: We bring the rollers to our factory in Boston, Lincolnshire and completely remove the old grit coating, before re-gritting with a new oven cured grit coating.

This coating will typically last as long as the original Original Equipment Manufacturer (OEM)  grit coating.

We have more than 20 years of experience in re-gritting brake tester rollers both for End Users, Garage Equipment Specialists and OEMs.

We re-grit all types and classes of brake tester rollers including HGV.

Our process restores the grip profile of your rollers, improves test accuracy, and extends the life of your existing equipment—delivering a cost effective solution that brings brake testers back to full performance without replacement.

Find a Garage Equipment Supplier with spare used “service replacement “ rollers: We work with Garage Equipment specialists who may have used “service replacement rollers” on hand that they can supply.

This should provide a good saving over the cost of new rollers and if we did the re-gritting for them, these rollers should give excellent life.

If you give us a call, we may be able to put you in touch with a Garage Equipment Supplier who could help.

On-site Re-gritting : If you are a busy MOT testing station with only one brake tester, you typically cannot do without your brake tester for more than one day.

In this situation, on-site re-gritting may be necessary. Our sub-contractors specialise in this type of work.

 They visit your site and take around half a day to grind off the old grit coating and apply a new grit coating that cures at ambient temperatures overnight.

The brake tester may be used again the next day.

This is the most convenient solution however for Brake Testers with heavy usage, the grit coating may only last a year or 18 months.

DIY Patching Kit : These kits may be found on the internet. They are rarely found to be more than a temporary solution.

Learn more about the service: www.porcher.co.uk/services/brake-tester-rollers