Eight pallets, two axles, and a dispatcher who only reads the total
You are loading a 7.5 t C1 truck with eight pallets of ceramic tiles, each weighing 400 kg. The truck's kerb weight is 4,250 kg. The manufacturer's plate gives front axle maximum 3,000 kg and rear axle maximum 4,500 kg. The wheelbase is 3.6 m. You place all eight pallets in two rows against the tail lift to speed up unloading. A weighbridge shows front axle 2,600 kg and rear axle 4,850 kg. The total is 7,450 kg, so the dispatcher says the truck is 'legal because it is under 7.5 t'. The load bed has a wooden floor, no friction mats, and the only lashing points are along the side rails. The tail lift is rated for 750 kg. You have 12 certified straps with LC 500 daN.
1. Is the dispatcher right? Calculate and explain.
Read the worked answer
No. The total weight is legal, because 7,450 kg is below the 7,500 kg vehicle maximum, but the axle limits are separate legal limits. The rear axle is at 4,850 kg against a 4,500 kg maximum, so it is overloaded by 350 kg. The front axle is at 2,600 kg against 3,000 kg, so it has 400 kg of spare capacity.
A weighbridge ticket that shows only the total would hide this. The rear axle is carrying too much because the pallets are loaded against the tail lift, well behind the rear axle. That increases rear-axle load and reduces steering-axle load. Driving like this is illegal and unsafe: the rear tyres are overloaded, the front may feel light, and braking stability is reduced.
2. What is the smallest practical change to the load that makes both axles legal? Show the weight-transfer calculation.
Read the worked answer
You need to move weight forward. Moving a pallet forward by distance d transfers approximately load x d / wheelbase from the rear axle to the front axle. Two pallets weigh 800 kg. Moving them 1.6 m forward gives 800 x 1.6 / 3.6 = 356 kg transfer. The rear axle becomes 4,850 - 356 = 4,494 kg, and the front becomes 2,600 + 356 = 2,956 kg. Both are legal, but the rear margin is only 6 kg, so re-weigh.
A more comfortable option is to move three pallets 1.1 m forward: 1,200 x 1.1 / 3.6 = 367 kg. Rear = 4,483 kg; front = 2,967 kg. That leaves about 17 kg on the rear and 33 kg on the front. In practice, redistribute the front row, re-weigh both axles, and only then close the doors. Never rely on the total weight alone.
3. How would you secure the pallets with the available equipment?
Read the worked answer
The tail lift is not a load restraint; it is rated for lifting, not for stopping 3.2 t of tiles in an emergency. Use the certified straps to secure the pallets to the side rails and, where possible, against the headboard. Because the floor is wooden and there are no friction mats, use top-over lashing over each pallet or direct lashing through the pallet openings, with edge protectors to prevent strap damage.
With 12 straps and eight pallets, plan the pattern so every pallet is restrained against forward, rearward and sideways movement. Tension the straps to the manufacturer's STF, check them after the first few kilometres, and re-check after braking. Keep the rear doors closed and do not leave loose pallets or offcuts behind the load. If the securing arrangement cannot be made compliant, do not drive.