Weighing In: Hydrovac Weight Limits Explained

Almost nothing can stop a hydrovac, but weight limits are one of the biggest challenges facing hydrovac operators today. Hydrovac weight restrictions are pretty strict, and for good reason; exceeding them can lead to serious performance issues and legal fines.

Keep reading to learn more about hydrovac weight limits and a few key tips for staying within them.

Hydrovac weight restrictions: a changing tide

For years, many hydrovacs mainly worked in an off-road capacity. Hydrovacs could often get away with breaches in weight rules because they operated in the oil and gas sector, on leased roads, or on remote sites where no one was checking scales or enforcing limits. 

In recent years, due to a downward trend in the oil industry, hydrovac work has shifted to the utilities and municipalities industry. Hydrovacs are now more frequently working on state and local roads, placing them in the public eye and subjecting them to increased scrutiny.

Weight compliance is a serious matter, and operators who disregard weight limitations can face substantial fines. Some weight-related hydrovac tickets can cost over $20,000!

Take Ontario, for example. For years, Ontario categorized hydrovacs as road-building machines (RBMs). This made hydrovacs exempt from weight limits! The bad news for hydrovac drivers is that this is no longer the case. Hydrovacs are now classified as commercial motor vehicles (CMVs), so they’re just as subject to weight limits as other vehicles.

In the US, commercial motor vehicles (CMV) are defined as motor vehicles used to carry passengers or cargo that have a gross vehicle weight rating (GVWR) or gross vehicle weight (GVW) of at least 26,001 pounds (or whatever lesser threshold the Secretary of Transportation prescribes, but not less than 10,001 pounds).

Many hydrovacs easily meet or exceed those weight levels and are used to transport materials, meaning the CMV classification applies; therefore, these vehicles are subject to weight regulations. 

The importance of vehicle weight

Weight limits aren’t just crucial for hydrovac operators. Anyone who uses a vehicle should be aware of how weight can affect performance.

A vehicle’s gross vehicle weight rating (GVWR) is the maximum amount of weight it can safely hold, including cargo, gear, and anything else weighing down the vehicle. Surpassing your vehicle’s GVWR can have serious ramifications, such as brake failure, tire blowouts, axle damage, and frame stress.

In short, an overweight vehicle will have diminished performance and won’t be as safe.

There’s also the legal element at play here. Different regions have varying weight restrictions for public roads, which are strictly enforced to ensure driver safety.

In addition to GVWR, hydrovac operators should be aware of:

Gross Vehicle Weight (GVW): the actual weight of the vehicle at any moment.

Gross Axle Weight Rating (GAWR): the maximum weight a single axle can safely carry.

Legal axle and bridge weight limits: regulated limits that apply on public roads regardless of the vehicle's own ratings.

As you load up your hydrovac, you must also think about:

Federal Bridge Law: Relates to axle number and spacing for vehicles on federal highways. Most hydrovacs are designed with these limits in mind.

State or provincial laws: Rules vary, including axle recognition and lifting axles (pusher or tag) allowances. Some locations do not count lifting axles toward weight capacities.

Seasonal and local restrictions: Frost laws, thaw restrictions, and municipal rules can create temporary or location-specific limits.

Axle spacing and configuration: Correct spacing can legally permit higher payloads while maintaining safety.

If you choose to ignore vehicle weight guidelines, you may find yourself in hot water when you’re suddenly responsible for paying hefty fines. These fines will vary depending on your location. In Florida, for instance, the penalty is $0.05 per pound for every pound over the legal weight of a commercial vehicle. 

In the Yukon, the fine is $200 if the excess weight is 1,000 kg or less. If a vehicle’s excess weight is greater than 1,000 kg, the fine is $200 plus $0.03 per tonne‑kilometer, or $350 plus $0.50 per tonne‑kilometer in some instances.

What weighs hydrovacs down?

Vehicle weight doesn’t come out of nowhere. When we’re talking hydrovacs, a lot of their weight comes from the debris being carried.

Hydrovacs are responsible for cleaning up all kinds of debris, such as mud, slurry, and wet clay, and the pounds can add up quickly, contributing to a hydrovac’s GVWR.

Dry sand, for example, can weigh between 2,600 and 3,000 pounds per cubic yard. Water weighs approximately 8.3 lbs/gallon, and dry dirt from 8.6 to 10.7 lbs/gallon.

Naturally, hydrovacs also need pressurized water in order to get jobs done. Hydrovacs range in capacity, with some models capable of holding up to 1,200 gallons of water. This is yet another factor that can impact vehicle weight.

Hoses, wands, vac extensions, toolboxes, fittings, and safety gear may seem like small additions, but together they can also add several hundred pounds.

Even when it’s empty, a hydrovac’s tank can weigh several thousand pounds, eating into available payload and pushing the overall GVWR even higher.

Keep things light

Keeping your hydrovac within weight limits isn’t just about avoiding fines. It’s about preserving your equipment and keeping you safe while operating your vehicle.

To keep your hydrovac at an appropriate weight, it’s essential to be aware of your region’s rules and regulations about weight. Manufacturer documents will typically let you know what your vehicle’s GVWR is, so you don’t go beyond it.

If you don’t know your region’s hydrovac weight limit, visit your local Department of Transportation (DOT) website for information.

One way to avoid overloading is to schedule frequent dumps. Instead of keeping debris for long periods, dispose of dirt, mud, or wet clay throughout the day to keep your hydrovac light.

Some hydrovacs even have shut-off systems and safety mechanisms implemented to prevent overload.  When a shut-off system recognizes that too much debris is being taken, it automatically halts the collection of new material.

Staying light is more than just a legal requirement. It’s the best way to maintain safety, performance, and long-term hydrovac reliability.