Pilot vehicle requirements in Australia

A pilot vehicle is enlisted to escort and support the safe transit of a heavy vehicle carrying oversized loads on public roads. To do this effectively, it must be kitted out with the right equipment to alert other motorists of the oncoming heavy vehicle.

Below, we explain the legislative criteria for these vital vehicles, their signs and warning lights. Read on to get a clear picture of pilot vehicle requirements in Australia.

This is a general guide only and is not intended as legal advice. If required, please consult a legal professional for personalised guidance before using a sign or light on your pilot vehicle.

What is a pilot vehicle?

According to Heavy Vehicle National Law (HVNL), a pilot vehicle is a motor vehicle that accompanies an Oversize Load, SPV or Agricultural Vehicle to warn other road users of its approach. That includes motorists, cyclists and pedestrians.

Note that an oversize vehicle is one that, either with or without its load, surpasses the weight, height, and width limits deemed safe for public roads. For example, a prime mover with an extendable trailer. This type of vehicle cannot be dismantled into lighter, lower or narrower components.

Meanwhile, an escort vehicle is a type of pilot vehicle driven by an individual who is permitted to direct traffic as per Australian road legislation, such as a Police Officer.

The escort driver’s role is not only to notify the presence of the oversize vehicle but also to facilitate its safe movement by guiding motorists accordingly.

When is a pilot vehicle required?

When a pilot vehicle is required depends on the national notices that apply in a given state or territory.

Made under the HVNL, a notice authorises a restricted access vehicle to travel on roads. It may also exempt certain vehicles from HVNL criteria.

While exact regulations vary by state, a pilot vehicle is usually not required on a road with an unobstructed view of oncoming traffic for at least 500m in both directions.

General requirements for pilot vehicles

Australia-wide oversize pilot vehicle requirements are detailed in Schedule 8 of the Heavy Vehicle (Mass, Dimensions and Loading) National Regulation. This legislation covers the use of warning signs and lights, pilot positioning, and driver communication.

Under Part 1, Division 5, a pilot vehicle is required to:

• Possess at least four wheels and a Gross Vehicle Mass (GVM) equal to or under 4.5 tonnes if only one pilot vehicle is being used. If two pilot vehicles are required, the rear pilot vehicle can have a GVM of up to 6.5 tonnes.
• Keep low-beam headlights activated when travelling during daylight hours.
• Never tow a trailer or carry a load, excluding tools, equipment, or materials needed for the oversize vehicle.
• Be equipped with a communication device that facilitates effective information transmission between the pilot vehicle and the vehicle it is accompanying. This is not a requirement for agricultural machinery.
• Feature a yellow rotating light at the highest feasible point on the vehicle, visible from 500 m in every direction.
• Mount a vertical, rigid yellow retro-reflective double-sided warning sign on its roof to display the message “OVERSIZE LOAD AHEAD”.

Additionally, the pilot driver must:

• Continuously evaluate and flag potential road risks.
• Deliver a visible warning to other road users about the oversize vehicle’s presence on the road.
• Share load dimensions with oncoming or passing vehicles, preferably through radio.
• Notify the oversize vehicle driver via radio of oncoming traffic, road conditions, bridge and traffic light status, clearance obstacles and other key updates.

 

What are the requirements for pilot signs?

Schedule 8 (Part 3, Division 2) of the regulations outlines specific requirements for pilot vehicle warning signs:

• A pilot vehicle is required to have a warning sign mounted on its roof.
• The sign should never tilt more than 200 mm from top to bottom.
• This sign must be a minimum of 1200 mm long and 600 mm high. If necessary for mounting, the sign can have corner cut-outs at the bottom, so long as each one remains under 150 mm long and 100 mm high.
• The sign must be made from materials fit for its purpose and display the manufacturer’s name or trademark, as well as the type and class of materials used on its face.
• The sign’s face has to have a yellow surface that conforms to Class 100 or 400 of the Australian Standard AS 1906.1 — 2017
• Retroreflective Materials and Devices for Road Traffic Control Purposes – Retroreflective Sheeting.
  On both sides, the sign should prominently display “OVERSIZE LOAD AHEAD,” visible from both front and rear:
  • “OVERSIZE” should be in black uppercase letters at least 200 mm high, following Australian Standard AS 1744 — 2015 Forms of Letters and Numerals for Road Signs, in Series C(N) typeface; and
  • “LOAD AHEAD” should be in black uppercase letters at least 100 mm high, as per the same Australian Standard in Series D(N) typeface.
  • The bottom edge of the “OVERSIZE” lettering should be at least 300 mm from the sign’s bottom, while the “LOAD AHEAD” lettering should be at least 100 mm from the bottom.
• Warning signs need to remain clean and clear at all times to ensure other road users can read them.

It’s important to be aware that displaying an “OVERSIZE LOAD AHEAD” sign when the vehicle is not operating as a pilot is a legal offence.

What are the requirements for pilot warning lights?

Schedule 8 (Part 3, Division 1) of the regulations sets out specific guidelines regarding warning lights:

• The warning lights must comply with the Australian Design Rules (ADR).
• On a pilot vehicle, the warning light should be placed either above or below the ‘Oversize Load Ahead’ sign, or on both sides of the sign.
• These warning lights need to be visible from 500 m in all directions.
• The warning lights should only be active while accompanying an oversize vehicle or Special Purpose Vehicle (SPV), and the driver must be able to turn them on and off from the standard driving position.
• When activated, these lights should emit a yellow light with a rotating and flashing effect, flashing between 120 and 200 times per minute.
• The lights should have a minimum power of 24W if using LED technology, or 55W with other technologies.
• The use of strobe lights as warning lights is prohibited.
• If warning lights are installed on a pilot vehicle leading an oversize vehicle, a filter can be placed behind the light to prevent it from blinding the oversize vehicle’s driver.

 

Where to position a pilot vehicle

On divided roads, a pilot vehicle needs to follow a heavy vehicle, whereas on undivided roads, it should be positioned in front.

If a class 1 heavy vehicle is accompanied by two pilot vehicles, one should lead at the front and the other should follow at the rear.

However, when this positioning is impractical or doesn’t provide sufficient warning to other road users, the pilot driver must adhere to specific position requirements outlined in the exemption conditions.

Pilot vehicles must maintain a distance from the heavy vehicle that allows ample warning time for other road users. This distance should be adjusted according to factors such as traffic speed, weather, visibility, and road conditions.

In scenarios where an escort vehicle is used in conjunction with a pilot vehicle, the escort driver may direct the positioning of the pilot vehicle.

Pilot driver accreditations

The Australian Capital Territory, New South Wales and South Australia do not require pilot drivers to be accredited. Agricultural vehicle pilots in Queensland also don’t need to have accreditation.

In contrast, pilot drivers in Western Australia must obtain a Heavy Vehicle Pilot Licence (HVPL). Criteria for this qualification are set out under the Road Traffic (Vehicles) Regulations 2014.

Meanwhile, a two-tier system operates across the Northern Territory, Queensland, Tasmania, and Victoria. In these states, there are two levels of pilot drivers, each with distinct requirements.

Queensland stands out as the sole state that applies this two-tier system to both pilot and escort vehicles.

Explore a full range of pilot safety products

Need reliable pilot vehicle warning lights and signs for your fleet?

Explore customisable solutions and get a quote online with Australian Warning Systems. From LED beacons to roof-mounted signage, our pilot driver products make it simple to alert road users of approaching oversize vehicles.

Enjoy peace of mind knowing our comprehensive range has been designed and manufactured to meet the highest standards of safety, performance and durability.

For more information, don’t hesitate to give our team a call at 03 9796 5880 or email us at [email protected]. Australia-wide delivery is available.