Alcoa, Metalsa Offer 2,500 lbs in Future Weight Savings

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Heavy Duty Trucking / April 5, 2015

Switching several major components from steel to aluminum could save up to 2,500 pounds on a typical class 8 truck. Speaking at the Mid-America Trucking Show, Alcoa’s VP & General Manager of Transportation Products Victor Marquez said the company has several products, either in service or development, that could clear the way for more than a ton of additional payload.

Alcoa, in collaboration with Metalsa, a global supplier of light and commercial vehicle and chassis structures, showcased several products currently in development, including aluminum frame rails, driveshaft tubes, suspension mounts, door skins and huck bolts.

Marquez says form-rolled aluminum frame rails can save 850 pounds over traditional steel frame rail.

"That's game-changing weight savings," he said. "On top of that, they do not rust so they will stay stronger longer with minimum maintenance."

According to Alcoa, the frame’s increased stiffness will double rigidity, enabling a smoother ride. The aluminum frame also offers superior corrosion resistance compared to steel, prolonging the vehicle’s life span.

Marquez says aluminum is about 45% of the weight of steel, so items like aluminum door skins and internal structures can save about 60 pounds per vehicle; an aluminum driveshaft can save about 100 pounds, an aluminum fifth wheel, currently offered by SAF Holland, saves about 100 pounds, and with about 250 huck bolts on a typical truck, count on weight savings of about 45% with no loss of structural integrity.

"How much is 2,500 pounds worth to a fleet? Different fleets value the weight savings differently," said Marquez. "Those that cube out before they weight out, probably not so much, but it's big bucks for reefer operators and fuel haulers. This miracle metal could help reshape the industry."

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