CCTV at the weighbridge — a practical setup guide

For yard supervisors, IT teams, and weighbridge vendors

Five years ago, CCTV on a weighbridge was a premium feature for govt-procurement sites. In 2026 it is standard at any yard handling more than 30 trucks a day. The reason is straightforward — disputes get resolved in 30 seconds with footage, dispatch fraud drops to zero when operators know they are recorded, and a growing list of govt RFPs make CCTV evidence mandatory at every weighment. This guide covers what a working CCTV install looks like at a weighbridge, how many cameras you need, the gear, the cabling, and the integration with your weighment software.

Why CCTV is now standard on weighbridges

Four things are driving CCTV adoption from optional to default:

• Truck-related disputes. Either a transporter claims their truck weighed more than the slip says, or a buyer claims it weighed less. Footage of the truck on the deck at the weighment time settles 90% of disputes immediately.
• Operator integrity. Yards that switched on CCTV typically see a measurable drop in operator-side weight inflation. The deterrent works even without anyone reviewing the footage.
• Tender / govt-procurement requirements. FCI procurement yards, Khanij Mitra mining sites, and many state weighbridges now mandate at least 4-channel CCTV with timestamped retention.
• WhatsApp + remote dispatch. Modern weighbridge software (including EagleOS) sends a still frame from the entry camera to the inspector's WhatsApp the moment a weighment completes — eliminating the need for the inspector to physically attend every weighment.

How many channels do you actually need

For most yards, the answer is 4 — but the right answer depends on the layout.

Where each camera should point

In a 4-channel install, the four cameras are not interchangeable. Each has a job. Get any one of them wrong and the whole system loses value.

1. Camera 1 — Entry approach. Mounted on a 4-5 m pole at the approach to the weighbridge, pointing at the truck as it approaches. Captures the front number plate before the truck enters the deck. This is the single most important camera; failure to capture the plate cleanly defeats most of the system's purpose.
2. Camera 2 — Bridge top / overhead. Mounted overhead on a gantry or building edge, pointing straight down at the centre of the deck. Captures the whole truck on the bridge, which is what dispute resolution actually needs.
3. Camera 3 — Indicator screen. Mounted close to the indicator display, pointing at the screen + the operator's hands. Captures the actual weight reading and the operator's slip-printing action. Useful for fraud detection and operator training.
4. Camera 4 — Exit + rear plate. Mounted at the exit gate, pointing back at the truck as it leaves. Captures the rear number plate (different from front in trucks with different registrations) and confirms the truck actually left.

Camera specs that matter at a weighbridge

Most CCTV camera spec discussions are dominated by megapixel counts. For weighbridges, the megapixel number matters less than four other specs.

• Low-light performance. Most weighments at busy yards happen at dawn or dusk. Choose cameras with f/1.4 or wider lens + back-illuminated sensors. 2 MP at f/1.4 beats 5 MP at f/2.8 for night-time plate capture.
• WDR (wide dynamic range). When a truck's headlights point at the entry camera, a non-WDR camera washes out and misses the plate. WDR 120 dB minimum.
• Outdoor weatherproofing. IP66 minimum for any outdoor mount. Look for "vandal-resistant" IK10 in mining yards.
• Power-over-Ethernet (PoE) support. Saves running separate power cables to each camera. Industry-standard PoE+ provides up to 30W per camera, enough for IR-illuminated outdoor units.

Megapixel-wise, 2-4 MP is the sweet spot for weighbridge cameras. 8 MP cameras are overkill — they generate twice the storage cost for marginal real-world benefit.

NVR vs DVR vs PC-based capture

• NVR (Network Video Recorder): the modern default. Cameras send IP video to the NVR over Ethernet. NVRs are purpose-built recording appliances with hot-swappable disks. Brand: Hikvision, Dahua, CP Plus.
• DVR (Digital Video Recorder): for analog cameras over coaxial cable. Still common at older yards. Lower upfront cost but limits future expansion + image quality.
• PC-based capture: a Windows machine with a video-capture card runs recording software. Tempting because it shares hardware with the weighment PC — but adds risk: if the recording software hangs, the weighment software hangs with it. We do not recommend it.

For a 4-channel install in 2026, a basic 8-channel NVR (CP Plus or Hikvision) with a 4 TB HDD covers 4 active channels + 4 future expansion at a cost of ₹14,000 – 22,000 for the NVR + drive together. PoE switches add ₹6,000 – 10,000.

Cable runs, conduits, surge protection

The thing nobody mentions in vendor pitches: cabling is often more expensive than the cameras themselves. A weighbridge yard has long cable runs, exposed outdoor segments, lightning exposure (especially in rural sites), and rodent damage. Budget for the cabling properly.

• Cable type: CAT6 STP (shielded) for IP cameras, RG-59 with 18-AWG power for analog. Outdoor runs need UV-resistant jacketing.
• Conduit: PVC conduit for indoor; galvanised steel for outdoor and underground. Direct burial is a recipe for rodent failure.
• Surge protection: install Ethernet surge protectors on every PoE line entering the NVR rack. Lightning takes out NVRs even from indirect strikes; surge protectors are cheap.
• Camera-to-NVR distance: CAT6 is good for 100 m without intermediate equipment. Beyond that you need PoE extenders or fibre.

For a typical 4-channel install with cameras 30-50 m from the NVR rack: ₹8,000 – 14,000 in cabling + conduits + surge protectors. For longer runs or hostile environments (mining yards) it can double.

Integrating CCTV with the weighment software

Modern weighbridge software (EagleOS included) integrates with the NVR via ONVIF or RTSP — open protocols that almost every NVR supports. Once integrated, each weighment captures:

• A still frame from each camera at the moment "print + sync" is hit
• A 30-second video clip from the bridge-top camera spanning the weighment
• The frame attached to the slip's PDF copy stored locally
• Optionally — sent over WhatsApp to the inspector or dispatch officer

This is what turns CCTV from a passive deterrent into an active dispute-resolution tool. A buyer disputes a weighment two weeks later? The frame is one click away from the slip number.

Storage retention — what tenders ask for

For continuous recording at 1080p across 4 channels, a 4 TB HDD holds approximately 30 days. A 6 TB drive holds approximately 45 days. Tenders specifying 90-day retention need 8-10 TB or two drives in a RAID configuration.

Realistic install timeline + cost

Install takes 1-2 days of technician time on site plus 1 day of software integration and operator handover. Most yards have working CCTV by the end of the same week as commissioning.

Read about the EagleOS integration for CCTV at the weighbridge or talk to the team for site-specific recommendations.

Last updated: June 2026 · Eagle Weigh editorial team