Prevent accidents with form-fitting load securing

Form-fitting load securing

July 18, 2025 | Tips for securing cargo

Prevent road accidents with form-fitting load securing

Form-fitting load securing for greater road safety

Responsibility for securing loads in road transport generally lies with the person who loads the vehicles, as well as the shipper and the driver. Depending on the load, those responsible usually choose between two types or a combination of two types of load securing: force-fit load securing and/or form-fit load securing. Where possible, form-fit load securing is always the first choice, as it not only increases road safety but also minimizes the risk of damage to vehicles and loads. Anyone planning to transport goods using form-fit load securing must know how physical forces, such as centrifugal and acceleration forces, work. Knowledge of the possible uses of other aids, such as lashing straps, strapping, edge protection, and anti-slip mats, is also necessary.

In this blog post, we explain when form-fitting load securing is used, explain the technology, and provide examples of its application.

What is form-fitting load securing?

With form-fitting load securing, the shape and arrangement of the transported goods essentially allow the load to be secured by itself. In order to minimize movement of the load during transport and achieve sufficient stability, the goods should be loaded "form-fitting" directly against the front wall, rear wall, and side walls without any gaps. The vehicle walls, edge protection, and lashing straps provide additional security for the load.

The following checklist will help you to load the goods correctly:

Loading is carried out seamlessly and on all sides against the vehicle body.
All load components must be stable enough to withstand the pressure of the load.
The load itself is also arranged in such a way that its weight is supported.
The cargo is stowed immovably.
Heavy cargo items in particular must be secured on all sides by dimensionally stable cargo.

Since it is rarely possible to meet all criteria one hundred percent, the load must also be secured with lashing straps and edge protection.

Techniques for securing loads with form-fitting devices

With the right technique, any form-fitting load securing can be achieved. Three rules of thumb that everyone should remember for correct application:

1. Heavy at the bottom, light at the top: Always stack your cargo correctly

To ensure a secure fit, heavy items must always be stacked at the bottom and light items at the top. This gives the transported goods a stable center of gravity and prevents them from slipping.

2. Create as much friction as possible

When securing loads with form-fitting restraints, there should always be points of contact between the individual items being transported and the vehicle walls. Where there are gaps, it is best to use appropriate aids. These can include anti-slip mats, filling materials, edge protectors, lashing straps, strapping bands, separating beams, nets, and much more. The more friction there is between the load components, the less the load will slip.

3. Arrange the packages according to their geometric shape.

Anyone who used to enjoy playing Tetris knows how it works. When securing loads with form-fitting fastenings, it is important to arrange the load so that it fits together well and supports itself. If necessary, use appropriate aids for this purpose.

What are the legal requirements for the use of form-fitting load securing?

The regulations laid down in law on load securing and, accordingly, form-fitting load securing vary from country to country and depending on the transport vehicle. In Germany, the legislation under §22 of the StVo (Road Traffic Regulations), "Load," applies. The techniques and rules for securing loads are also part of guidelines (VDI 2700 ff), information from professional associations and European standards (DIN EN), and regulations as specified by the DGUV (German Social Accident Insurance). The rules and regulations for load securing specify exactly who is liable and what specific requirements apply to the accuracy of fit and the quality of the connecting elements. In addition, regular maintenance of the load securing equipment used, as well as continuous training for users and those responsible for load securing, must be carried out and recorded.

Examples of form-fitting load securing applications:

In many cases of load securing, a combination of form-fit and force-fit is used to ensure that loads are roadworthy for transport. Purely form-fit load securing is always possible when, for example, pallet loads or container deliveries can be transported evenly and without gaps. Building materials – e.g., stone slabs or bricks – can also be arranged evenly and without gaps by the shipper so that form-fit works well. However, as these materials are very heavy, tongue-and-groove systems or special locking mechanisms are used to provide additional support and secure the goods.

Conclusion: Form-fitting load securing

A purely form-fitting load securing system is used when the load to be transported fits snugly and is flush with the walls of a transport vehicle. Like all load securing systems, form-fitting load securing is subject to strict regulations and is governed by law. It is usually used in combination with force-fitting load securing. However, if it can be used, for example when loading pallets, it is always recommended because it is cost-effective and safe for transport. Shippers should always ensure that there are large friction surfaces between the packages, which may need to be created with additional filling material. The highly adhesive Sander edge protection and Sander strapping provide additional protection for the load.