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MENTAL PROTECTION AGENCY »
U.S. ENVIRONMENTAL PROTECTION AGENCY
Weight Reduction
A Glance at Clean Freight Strategies
ENERGY &
FUEL SAVINGS
Gallons Saved:
240 gallons
CO2 Savings:
2.44 metric tons
Fuel Cost Savings:
$912
Choosing lighter-weight tractor and trailer components can reduce truck weight
by thousands of pounds. Reducing 3,OOO pounds from a heavy truck could save
24O gallons of fuel each year, eliminating from 2 metric tons of greenhouse gas
emissions annually.
What is the challenge?
Truck fuel consumption increases with the weight of the vehicle. Many truck components are
typically made of heavier material, such as steel. Heavier trucks require more fuel to accelerate
and to climb hills, and may reduce the amount of cargo that can be carried.
What is the solution?
Every 1 0 percent drop in truck weight reduces fuel use between 5 and 1 0 percent. Generally, an
empty truck makes up about one-third of the total weight of the truck. Using aluminum, metal
alloys, metal matrix composites, and other lightweight components where appropriate can reduce
empty truck weight (known as "tare weight"), improve fuel efficiency, and reduce greenhouse gas
emissions.
Most truck manufacturers offer lightweight tractor models that are 1,000 or more pounds lighter
than comparable models. Lighter-weight models combine different weight-saving options that
may include:
• Cast aluminum alloy wheels can save about 40 pounds each for total savings of
about 400 pounds
• Aluminum axle hubs can save over 120 pounds compared to ductile iron or steel
• Centrifuse brake drums can save nearly 100 pounds compared to standard brake
drums
• Aluminum clutch housing can save about 50 pounds compared to iron clutch housing
• Composite front axle leaf springs can save about 70 pounds compared to steel springs
• Aluminum cab frames can save hundreds of pounds compared to standard steel
frames
• Downsizing to a smaller, lighter-weight engine can save over 700 pounds
Truck trailers offer additional options for weight savings. Lightweight components
that can reduce empty trailer weight by 2,000 pounds or more may include:
• Aluminum roof bows save about 1 00 pounds compared to steel
• Aluminum floor crossmembers save approximately 1 60 pounds
compared to steel
• Aluminum floor saves about 375 pounds compared to 1 -3/8"
laminate hardwood
• Aluminum side posts save approximately 300 pounds compared
to steel
• Aluminum hubs or light weight cast iron hubs save about
30 pounds per axle compared to standard cast iron hubs
• Light weight brake drums save about 45 pounds per axle
compared to standard cast iron brake drums
Continued
U.S. EPA SmartWay | EPA-420-F-16-028 | June 2016 | www.epa.gov/smartway
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SmartWay
MENTAL PROTECTION AGENCY »
U.S. ENVIRONMENTAL PROTECTION AGENCY
Weight Reduction
A Glance at Clean Freight Strategies
Continued
• Eight aluminum wheels save about 225 pounds compared to eight steel wheels
• Composite trailer springs can save about 70 pounds compared to steel springs
Lighter-weight alternative materials can cost more. Therefore, use of lighter-weight truck options is more common in freight
applications that are weight-sensitive, like heavy-goods and refrigerated foods. However, virtually any truck fleet could employ
weight saving strategies.
Savings and Benefits
Trimming 3,000 pounds from a heavy truck (about four percent of its loaded weight) with lighter-weight components could save
240 gallons of fuel each year. Saving this much fuel would eliminate between 2 metric tons of greenhouse gas emissions per
year. Trucks that employ more weight-saving options would save more. In addition, in weight-sensitive applications, lightweight
components can allow more cargo and increased productivity.
NEXT STEPS
IWhen specifying
new trucks, truck-
ing fleets should
consider the lightest-
weight components
that will suit the
application and
where appropriate,
buy lighter-weight
versions of stan-
dard truck models.
One manufacturer,
for example, offers
a day-cab tractor
that weighs 2,100
pounds less than the
base model. Another
manufacturer offers
a 1,200 pound lighter
version of a popu-
lar sleeper model,
intended for dry and
liquid bulk haulers as
well as other weight
sensitive operations.
2Most truck manu-
facturers and
dealers can provide
additional informa-
tion on weight-
saving options.
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