SmartWay Transport | EPA420F09-043 | www.epa.gov/smartway | 734-214-4767 | smartway_transport@epa.gov

Weight Reduction

A Glance at Clean Freight Strategies

Energy

and 

Fuel Savings

1 When specifying new 

trucks, trucking fleets 

should consider the lightest-weight components 

that will suit the application and where appropriate, buy lighter-weight 

versions of standard 

truck models. One manufacturer, for example, 

offers a day-cab tractor 

that weighs 2,100 pounds 

less than the base model.

1 continued Another 

manufacturer offers 

a 1,200 pound lighter 

version of a popular 

sleeper model, intended for dry and liquid 

bulk haulers as well as 

other weight sensitive 

operations.

2 Most truck manufacturers and dealers 

can provide additional 

information on weightsaving options.

Next Steps

.

Choosing lighter-weight tractor and trailer components can reduce truck weight 

by thousands of pounds. Reducing 3,000 pounds from a heavy truck could save 

240 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 10 percent drop in truck weight reduces fuel use between 5 and 10 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 100 pounds compared to steel

• Aluminum floor crossmembers save approximately 160 pounds compared to steel

Gallons Saved 

= 

240 gallons

Fuel Cost Savings

= 

$912 

CO2 Savings 

= 

2.44 Metric tons
Weight Reduction

SmartWay Transport | EPA420F09-043 | www.epa.gov/smartway | 734-214-4767 | smartway_transport@epa.gov

• 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 

• 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 weightsensitive applications, lightweight components can allow more cargo and increased productivity.

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