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 between 200 and 500 gallons of fuel each year, eliminating from 2

to 5 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 40

pounds each for total savings of 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 50

pounds compared to iron clutch housing

! Composite front axle leaf springs can save

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 posts can save

approximately 75 pounds

! Aluminum floor joists can save about 300

pounds

! Aluminum upright posts can save

approximately 600 pounds

! Aluminum hubs and wheels can save about

900 pounds

Lighter-weight alternative materials can cost more.

According to truck retailers, lighter-weight truck 

tractors cost about $2,000 more than comparable

standard models. Trailer manufacturers report a

similarcost premium. 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. 

The results are in . . . 

Trimming 3,000 pounds from a heavy truck (about

four percent of its loaded weight) with lighter-weight

components could improve fuel economy by up to 3

percent and save between 200 and 500 gallons of

fuel each year. Saving this much fuel would eliminate

between 2 to 5 metric tons of greenhouse gas

emissions per year. Trucks that employ more weightsaving options would save more. In addition, in

weight-sensitive applications, lightweightcomponents

can allow more cargo and increased productivity.

Next steps

When specifying new trucks, trucking fleets should

consider the lightest-weight components that will suit

the application and where appropriate, buy lighterweight versions of standard 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 popular sleeper model, intended for dry

and liquid bulk haulers as well as other weight

sensitive operations. Most truck manufacturers and

dealers can provide additional information on weightsaving options.