What this is
What is a load plan and build record?
What is a load plan and build record?
It sets out how a vehicle will be loaded before loading starts: weight distribution front to rear, axle loading, stop sequence and product segregation. It is completed for multi-drop and mixed loads by transport planning, and it is a singleton in KnowLogistics, set up once per workspace rather than freshly designed for every load.
What is the difference between checking gross weight and planning weight distribution?
Gross weight only confirms the vehicle is not carrying too much overall. Distribution decides where that weight sits front to rear and across axles, which is what actually keeps individual axle loads legal. A vehicle can be well within its gross weight limit and still fail on one overloaded axle if the distribution was never planned.
Why does a weight and axle document also cover segregation?
Because a legally loaded vehicle can still carry a contamination or crush risk. Allergen segregation, chemical and food separation, raw versus ready-to-eat product and temperature zones sit alongside axle limits because both categories of failure are decided at the planning stage, before the vehicle leaves the yard.
Scope
When is a load plan and build record required?
This record is one step in a larger programme. Using it for work that belongs to a neighbouring template produces records that are hard to report on later.
Use this template when
- A multi-drop or mixed load is about to be built and needs its weight, sequence and segregation decided before loading starts
- A vehicle configuration or route has changed in a way that affects axle loading or drop sequence
- The workspace is being set up, or the register needs an entry added or retired
- You are running the Outbound and Despatch programme and this is one of its steps
- A linked record needs this one to exist, since it links Weight and Axle Check and Load Securement
Do not use it for
- Load Tender Record, which records a load offered to a carrier, the rate agreed and whether it was accepted or refused, before any plan for building it exists.
- Weight and Axle Check, which verifies the vehicle against its limits at the point of loading, rather than deciding the distribution in advance.
- Load Securement Check, which confirms the load is physically restrained as loaded, not how it was planned to be built.
- Dispatch Release Check, which is the final check before a load leaves, covering documents, temperature, securement, seal and count.
- Anything outside KnowLogistics, which belongs in the workspace that owns that process
Compliance mapping
Which FMCSA 393 Subpart I requirements does this satisfy?
Weight and axle limits sit under federal size and weight law, not FMCSA safety regulation directly, while cargo securement and food segregation come from separate instruments again; this record is where all three meet before the vehicle moves.
| Clause | Requirement | Where it lands |
|---|---|---|
| 23 U.S.C. § 127 (Federal Bridge Formula) | Gross and axle weight limits are calculated from axle spacing, not from total payload alone, and have to be respected before the vehicle is loaded. | Header |
| 23 CFR Part 658 (federal truck size and weight limits) | Individual axle weights and gross vehicle weight must fall within the limits set for the vehicle's configuration and the roads it will use. | Weight and axles |
| 49 CFR Part 393 Subpart I (§393.100–136) | Weight distribution front to rear has to keep cargo secured against shifting, not merely keep the vehicle under its gross weight limit. | Weight and axles |
| FSMA Sanitary Transportation Rule (21 CFR Part 1, Subpart O) | Raw and ready-to-eat product, and product held at different temperature zones, must be kept from cross-contaminating one another in transit. | Sequence and segregation |
| 49 CFR Part 177 (hazardous materials segregation table) | Chemical and food product carried on the same vehicle must be segregated according to the compatibility rules for the substances involved. | Sequence and segregation |
| 49 CFR Part 393 Subpart I (§393.100–136) | Restraint points and the unloading method at each drop have to be planned so the load stays secured until the vehicle reaches its final stop. | Practicality |
| 23 U.S.C. § 127 (Federal Bridge Formula) | A plan is only compliant if the vehicle is loaded and driven as planned; a deviation recorded after delivery signals the plan itself needs revisiting. | Outcome |
What it does not cover
- Axle Loading Calculated, which is marked Yes without anyone actually running the numbers against the vehicle's axle spacing.
- Allergen Segregation Planned, which is defaulted to Yes even when the load carries no allergen-declared product for it to actually apply to.
- Loader Briefed On The Plan, which is ticked Yes when the loader was only handed a pick list, not the plan showing sequence and weight distribution.
- Weighbridge Check Planned, which is Yes on the plan but never happens in practice because the site's weighbridge is out of action that day.
- Plan Followed, which is marked Yes with Deviation Detail left blank, even though Actual Weight differs meaningfully from Total Weight Planned.
Global
Load Plan and Build Record requirements by country
FMCSA cargo securement rules give this template one anchor, but the weight and axle limits it plans against come from a separate body of law, and that law changes the moment a load crosses a border.
23 U.S.C. § 127 (Federal Bridge Formula) and 49 CFR Part 393 Subpart I
Federal weight limits and cargo securement rules apply on the interstate highway system, calculated from axle spacing rather than payload alone.
Axle loading has to be calculated against the Bridge Formula for the vehicle's actual configuration, not just checked against a single gross weight figure.
CCMTA Memorandum of Understanding on Interprovincial Vehicle Weights and Dimensions, applied through provincial highway traffic regulations; NSC Standard 10 for cargo securement
Canadian provinces set their own axle group and gross weight limits under the CCMTA MOU and their own highway traffic regulations, which diverge from the US Bridge Formula in the numbers they allow.
A plan built to US axle limits does not automatically clear a Canadian province's own limits, so a cross-border load plan has to be checked against both regimes, not one.
Road Vehicles (Construction and Use) Regulations 1986 and EU Directive 96/53/EC on weights and dimensions
Sets maximum weights, individual axle loads and vehicle dimensions for goods vehicles operating within the UK and across the EU.
The same plan-before-loading discipline applies, but against an entirely different set of axle and gross weight figures than the US Bridge Formula produces.
How to complete it
How to complete a load plan and build record, step by step
Filling in every field is mechanical. The judgement calls below decide whether the plan actually held once the vehicle left the yard.
The record's name covers both a plan and a build, and the two only differ if the plan comes first. Whether planning actually completes this before the loader starts, rather than describing what already happened, decides whether the record can prevent anything at all.
Allergen Segregation Planned, Chemical And Food Segregated and Raw And Ready To Eat Segregated all invite a reflexive Yes on loads that don't actually carry the product types they're meant to separate. Someone has to judge whether the answer reflects a real decision or the easiest box to tick.
Loader Briefed On The Plan and Driver Briefed On The Sequence can both be answered Yes on the strength of a two-minute handover that never actually communicated weight distribution or stop order. The record only means what it says if briefing involved the plan itself.
Actual Weight sits next to Deviation Detail, but nothing forces the two to be reconciled. Deciding how large a gap between planned and actual weight warrants a written deviation, rather than a shrug, decides whether the plan-followed metric means anything.
What auditors find
Most common load plan and build record findings
The specific ways this record fails to hold up later, tied to the fields that let the failure happen.
| Finding | Clause | What fixes it |
|---|---|---|
| Axle Loading Calculated is marked Yes without anyone running the numbers against the vehicle's actual axle spacing. | 23 CFR Part 658 | Require the calculation itself, or a reference to it, before this field can be answered Yes; a tick box is not a calculation. |
| Loader Briefed On The Plan is ticked Yes when the loader was handed a pick list rather than the actual weight and sequence plan. | 49 CFR Part 393 Subpart I (§393.100–136) | Make the briefing evidence-based, a copy of the plan handed over or walked through, rather than a status the planner asserts on the loader's behalf. |
| Allergen Segregation Planned defaults to Yes regardless of whether the load carries allergen-declared product at all. | FSMA Sanitary Transportation Rule (21 CFR Part 1, Subpart O) | Force a genuine assessment of the load's product mix before this field is answered, rather than treating Yes as the safe default. |
| Weighbridge Check Planned is Yes on the plan but never happens because the site's weighbridge is out of action that day. | 23 U.S.C. § 127 (Federal Bridge Formula) | Tie this field to an actual weighbridge event, and require a fallback plan when the weighbridge is unavailable rather than silently skipping the check. |
| Plan Followed is marked Yes with Deviation Detail left blank despite Actual Weight differing meaningfully from Total Weight Planned. | 23 U.S.C. § 127 (Federal Bridge Formula) | Set a tolerance between planned and actual weight beyond which Deviation Detail becomes mandatory before the record can be marked complete. |
| Restraint Points Planned is answered Yes with no matching Securement Check ID ever populated in the Outcome section. | 49 CFR Part 393 Subpart I (§393.100–136) | Treat the Securement Check ID as the evidence for this field, not an optional cross-reference filled in whenever convenient. |
Case in point
Case in point: a plan that was accurate on paper and wrong on the vehicle
A mixed chilled and ambient load was planned correctly: heavy items positioned low, axle loading calculated within limits, drops sequenced in reverse order for a five-stop route. Transport planning signed it off and moved on, confident the numbers worked.
The loader, working from a pick list rather than the plan itself, built the vehicle in whatever order stock came off the racking. Weight ended up over the rear axle, and product for the first drop was buried behind the last. Plan Followed In Practice was marked Yes anyway, since nobody checked the build against it; the first customer got a delivery that arrived crushed and out of sequence, and Any Damage On Delivery told a story the plan never predicted.
The template
The template, field by field
The form exactly as it installs. Every field, option, score and conditional rule is editable, and the links to other templates come with it.
5 sections
- Reference
- LOG-011
- Archetype
- Record
- Record ID
- LPLN-2026-000
- Scoring
- Plans followed
- Direction
- High is good
- Singleton
- Yes
- Basis
- FMCSA 393 Subpart I
- Links
- Links Weight and Axle Check and Load Securement
- Tags
- Outbound, Loading
- Sections
- 5
- Fields
- 50
- Follow up fields
- 3
- Repeating sections
- 0
- Links out
- 4
Header
13 fieldsPlan ID*
Auto sequence. Format LPLN-2026-000.
The record's own ID. Other templates point at this value.
Status*
Drives who this goes to next.
- Planned2 pts
- In progress2 pts
- Complete3 pts
- Deferred0 pts
- Open0 pts
- Closed3 pts
- Overdue0 pts
Date and Time*
Completed By*
Site*
Site ID*
Format SITE-000.
Links to FDN-001 Site ID
Load Reference*
Drops On This Load*
Total Weight Planned*
Vehicle Type*
Payload Limit*
Within Payload*
- Yes2 pts
- No0 pts
- N/Aexcluded from denominator
Axle Overloads Are Planned, Not Accidental
A vehicle is not overloaded at the weighbridge, it is overloaded on the plan. Stop sequence, weight distribution and segregation are all decided before anybody picks up a pallet.
Weight and axles
6 fieldsAxle Loading Calculated*
- Yes2 pts
- No0 pts
- N/Aexcluded from denominator
Front To Rear Distribution Planned*
- Yes2 pts
- No0 pts
- N/Aexcluded from denominator
Within Gross Vehicle Weight*
- Yes2 pts
- No0 pts
- N/Aexcluded from denominator
Within Individual Axle Limits*
- Yes2 pts
- No0 pts
- N/Aexcluded from denominator
Heavy Items Positioned Low*
- Yes2 pts
- No0 pts
- N/Aexcluded from denominator
Weighbridge Check Planned*
- Yes2 pts
- No0 pts
- N/Aexcluded from denominator
Sequence and segregation
6 fieldsLoaded In Reverse Drop Order*
- Yes2 pts
- No0 pts
- N/Aexcluded from denominator
Allergen Segregation Planned*
- Yes2 pts
- No0 pts
- N/Aexcluded from denominator
Chemical And Food Segregated*
- Yes2 pts
- No0 pts
- N/Aexcluded from denominator
Raw And Ready To Eat Segregated*
- Yes3 pts
- No0 pts
Temperature Zones Respected*
- Yes2 pts
- No0 pts
- N/Aexcluded from denominator
Crush Risk Considered*
- Yes2 pts
- No0 pts
- N/Aexcluded from denominator
Practicality
6 fieldsPlan Achievable With Available Equipment*
- Yes2 pts
- No0 pts
- N/Aexcluded from denominator
Loader Briefed On The Plan*
- Yes2 pts
- No0 pts
- N/Aexcluded from denominator
Driver Briefed On The Sequence*
- Yes2 pts
- No0 pts
- N/Aexcluded from denominator
Restraint Points Planned*
- Yes2 pts
- No0 pts
- N/Aexcluded from denominator
Unloading Method At Each Drop Known*
- Yes2 pts
- No0 pts
- N/Aexcluded from denominator
Plan Followed In Practice*
- Yes2 pts
- No0 pts
- N/Aexcluded from denominator
Outcome
19 fieldsPlan Followed*
- Yes2 pts
- No0 pts
- N/Aexcluded from denominator
Deviation Detail
Actual Weight
Weight Check ID
Links to FLT-024 Check ID
Securement Check ID
Links to FLT-023 Check ID
Any Damage On Delivery*
- Yes0 pts
- No2 pts
- N/Aexcluded from denominator
Items Assessed*
Excludes anything marked N/A.
Items Failed*
Score Percent*
Calculated on submission. High is good. N/A items leave the denominator.
Result Band*
- Pass3 pts
- Caution1 pt
- Fail0 pts
Completeness Percent*
How much of the template was actually answered. A high score on a half completed form is not a high score.
Action Required*
Raise the action record, then enter its reference here.
- No2 pts
- Yes0 pts
Priority
- High0 pts
- Medium1 pt
- Low3 pts
CAPA ID
Format CAPA-2026-00000.
Links to FDN-014 CAPA ID
Action Owner
Transport Planner*
Signature*
Despatch Supervisor*
Second Signature*
LOG-011 · record IDs look like LPLN-2026-000 · Links Weight and Axle Check and Load Securement
Open in KnowellaRun it with agents
From a document you fill in to a programme that runs itself
The form is the easy part. Keeping it current and holding the evidence together is the work that actually slips.
Holds the load plan and build register against your load references, links each plan to its Weight and Axle Check and Load Securement Check, and keeps the planned-versus-actual weight comparison visible.
Connects the vehicle's own axle configuration and payload history to the plan, so a recurring axle overload pattern on one vehicle type is visible rather than treated as a one-off.
Picks up crush risk and manual handling considerations from the plan, so heavy-item positioning and restraint points feed the same safety picture as the loaders actually building the vehicle.
Coordinates the crew, rolls plan-followed and deviation data into one view, and holds every write for your approval before it touches a record.
This template lives in KnowLogistics — supply chain execution. Inbound, outbound, inventory, yard, claims, supplier lifecycle and customs.
Glossary
Load Plan and Build Record definitions and key terms
- LPLN
- The mint code for this record type: a load plan and build record, one per vehicle load rather than one per delivery stop.
- Federal Bridge Formula
- The US calculation, set out at 23 U.S.C. § 127, that limits axle weight based on axle spacing rather than a flat per-axle number, so closer axles must carry less.
- FMCSA
- Federal Motor Carrier Safety Administration, the United States regulator for commercial road transport safety, including cargo securement under 49 CFR Part 393.
- NSC Standard 10
- The Canadian National Safety Code cargo securement standard, adopted by the provinces and harmonised with 49 CFR Part 393 Subpart I, so the same securement principles apply on both sides of the border.
- Segregation
- Physically separating incompatible product categories on the same vehicle, such as allergens, chemicals and food, or raw and ready-to-eat items, to prevent contamination in transit.
FAQ
Frequently asked questions about load plan and build record
Does a single-drop load need one of these records?+
The template is stated as completed for multi-drop and mixed loads specifically. A single-drop, single-product load carries far less sequencing and segregation risk, though weight and axle limits still apply regardless of drop count.
What is the difference between this and the Weight and Axle Check?+
This record is the plan, decided before loading starts. Weight and Axle Check verifies the vehicle against its limits at the point of loading. The two are linked by Weight Check ID so the check can be traced back to the plan it is confirming.
Why does axle loading matter if the vehicle is under its gross weight limit?+
Gross weight and axle weight are different limits, calculated differently. A vehicle can sit comfortably under its gross weight and still overload one axle if distribution front to rear was never planned properly.
Who signs off this record?+
Transport Planner completes the plan and Despatch Supervisor provides the second signature, matching the two-stage structure most singleton records in this workspace use.
What happens if the plan is followed but damage still occurs?+
Plan Followed and Any Damage On Delivery are scored independently in the Outcome section. A plan can be followed exactly and still fail to prevent damage, which is itself useful information about whether the plan was adequate.
How is a load plan and build record scored?+
Scoring is plans followed, with high as good. It measures whether the plan drawn up before loading was actually the plan the vehicle was built and driven to, not just whether the paperwork exists.
Keep going
Related templates and programmes
Industries this is written for
Programmes this belongs to
Used together in Outbound and Despatch
Load Securement Check
Confirms the load is secured correctly for its type, weight and journey
Weight and Axle Check
Records gross weight and axle loading against legal limits
Load Tender Record
Records a load offered to a carrier, the rate agreed and whether it was accepted or refused
Dispatch Release Check
The final check before a load leaves, covering documents, temperature, securement, seal and count
Shipping Document Check
Verifies the bill of lading, packing list, certificates and any regulated documentation before the vehicle moves
Proof of Delivery Exception
Records a delivery that did not complete cleanly: refused, short, damaged, late or signed with a notation
More in Outbound
Load Tender Record
Records a load offered to a carrier, the rate agreed and whether it was accepted or refused
Dispatch Release Check
The final check before a load leaves, covering documents, temperature, securement, seal and count
Shipping Document Check
Verifies the bill of lading, packing list, certificates and any regulated documentation before the vehicle moves
Proof of Delivery Exception
Records a delivery that did not complete cleanly: refused, short, damaged, late or signed with a notation
Customer Delivery Confirmation
Confirms what the customer actually received against what was despatched
Written and reviewed by
Siddarth Singh
Founder & Chief Executive Officer, Knowella
Certified Safety Professional and industrial and systems engineer with more than a decade inside food supply chain, freight and manufacturing operations. This page was written against the current text of the standards it cites, not against secondary summaries of them.
- Certified Safety Professional (CSP), Board of Certified Safety Professionals
- MBA, University of Chicago Booth School of Business
- MS and BS, The Ohio State University, Industrial and Systems Engineering
- Six Sigma Black Belt
Sources and last review. Reviewed 16 August 2026 against:
- FMCSA 393 Subpart I — Protection Against Shifting or Falling Cargo (49 CFR §393.100–136)
- 23 U.S.C. § 127 — Federal Bridge Formula
- FSMA Sanitary Transportation Rule — 21 CFR Part 1, Subpart O
- CCMTA Memorandum of Understanding on Interprovincial Vehicle Weights and Dimensions; NSC Standard 10 — Cargo Securement
This page is general guidance, not legal advice. Confirm requirements with your jurisdiction’s regulator.