How Safety [in numbers] is Engineered

into Truck Bodies

Josh Swank
Philippi-Hagenbuch, Inc.

.2009 Philippi-Hagenbuch, Inc

Numbers?

1. Factors that Destroy

2
2. Ground Clearance at Full Dump
3. Width and how it relates to loading
4. Body Weight
5. Loader Reach
6. Construction | Superstructure
p
7. Material Angles of Repose | Material Density
8. Rated Capacity
p y | Loading
g Factors

.2009 Philippi-Hagenbuch, Inc

Body Floor

.2009 Philippi-Hagenbuch, Inc

Factors that Destroy

1. Abrasive wear
2. Mass impact
3. Projectile impact
4
4. Haul cycle frequency
5. Type and size of loading equipment
6
6. Body inside width relative to load centering / impact
7. Dump site / tail chute damage
8
8. Loading equipment damage
.2009 Philippi-Hagenbuch, Inc
Abrasive Wear
Body components that come in contact with hauled
material
Strength of steel / abrasion resistant
Must be built to withstand thinning over time
Minimize sidewall abrasion
Tapering body sides allow better load release

.2009 Philippi-Hagenbuch, Inc

Mass Impact
Occurs when truck is loaded in two to three passes
240 ton truck loaded with (3) 80 t 120 t / pass
Body floor support structure is key

.2009 Philippi-Hagenbuch, Inc

Mass & Projectile Impact
Sharp material projectile impact occurs with:
Sharp
Large materials
Chunky
Creates an armor piercing situation
Steel should be a derivative of steel armor plate
p
Mass impact affects whole truck / body vibration
that is a safety concern for truck drivers

.2009 Philippi-Hagenbuch, Inc

Mass & Projectile Impact

.2009 Philippi-Hagenbuch, Inc

Mass & Projectile Impact
Reduced material discharge height directly relates
to whole truck / body vibration
Pass after pass, load after load, vibration can affect
the human body

.2009 Philippi-Hagenbuch, Inc

Haul Cycle Frequency
More loads dropped, hauled and dumped by truck
body, the more stress the body incurs
What does 20,000 hours of body life mean?
Is it 5 loads / an hour = 100,000 loads
Is it 1 load / an hour = 20,000 loads
Body must be bult to withstand number of loading /
dumping cycles it will be subjected to, just just the
number of hours in operation

.2009 Philippi-Hagenbuch, Inc

Type and Size of Loading Equip.
Three main types of loading equipment:
Cable Shovel
Hydraulic Shovel
Front End Loader

.2009 Philippi-Hagenbuch, Inc

Cable Shovel
Large cable shovels (80 120 ton bucket
capacities) incur:
Higher loading impacts
Less favorable load placement
Bodies are often loaded off-center
Potentially causes body twist

.2009 Philippi-Hagenbuch, Inc

Hydraulic Shovel
Load is often closer to center
Material drop (projectile impact) remains similar
between cable and hydraulic shovels

.2009 Philippi-Hagenbuch, Inc

Front End Loader
Typically drop material further than cable or
hydraulic shovels
Causes greater impact to body side and often
adversely impacts body life

.2009 Philippi-Hagenbuch, Inc

Body Inside Width
Wider bodies provide easier loading target
Allows cable and hydraulic shovels to place
material into center of bodies
Material impact decreases the closer to the floor
the material is discharged
Loading equipment damage is minimized where
possible
ibl with
ith th
the correctt lloading
di equipment
i t / ttruck
k
match

.2009 Philippi-Hagenbuch, Inc

Body Loading Narrow Body

Narrow bodies are harder to load and Wider bodies are easier to load
often have poor load placement and achieve proper load placement
.2009 Philippi-Hagenbuch, Inc
Body Loading Wider Body

.2009 Philippi-Hagenbuch, Inc

Weight
Body weight directly relates to the amount of
material being hauled
Floor thickness: 51% - 59%
Body Sides: 14% - 21%
Front Slope: 10% - 12%
Canopy:
C 6% - 10%
Other: 6% - 9%

.2009 Philippi-Hagenbuch, Inc

Body dump / tail chute damage
Highest practical tail chute dump clearance
needed
Two ways of achieving:
1. Body design floor configuration
2. Angle of body floor dump to release material
from the truck body (typically 45 floor angle at
f ll d
full dump))

.2009 Philippi-Hagenbuch, Inc

Dump Clearance

.2009 Philippi-Hagenbuch, Inc

Loading Equipment Damage
When there is a loading equipment / truck
mismatch, damage to body sides, and loader
b k t
bucket
Results in costly maintenance and unnecessary
equipment downtime

.2009 Philippi-Hagenbuch, Inc

Combating these Factors
Body Design is Key
User buy-in
Discuss expectations in advance
Design and build to the end users expectations
Know the application and design accordingly
Correctly size the body
Use the correct materials for the job
Qualityy welding
g consumables is imperative
p

.2009 Philippi-Hagenbuch, Inc

Body Weight
Understanding end users expectations can help
determine the weight of a body
1 load an hour or 5 loads and hour?
Projected / intended body life
Abrasiveness of material being hauled
Loading tool / potential projectile impact

.2009 Philippi-Hagenbuch, Inc

Loader Reach
Type of loader affects overall width of body
Body should be designed for load to be centered
Truck & Body / Loader mismatch can affect
productivity
Important to know make/model of loader with
options prior to beginning body design

.2009 Philippi-Hagenbuch, Inc

Construction | Superstructure
Reinforced body superstructure imperative to
support load in body, regardless of type of body
A solid superstructure is the foundation of any body
What value is there in a floor with no natural
seems? ?
Less cracking and breaking of steel
Longer body floor life
Less maintenance / downtime

.2009 Philippi-Hagenbuch, Inc

Body Sizing
Why are Material Densities and Angles of Repose
important?
How does the material I carry affect the rated
capacity of my truck body?
Why is my body holding 15% % less than the SSAE
rated capacity?

.2009 Philippi-Hagenbuch, Inc

Body Sizing
Bodies are typically sized using the SAE 2:1 Heap
Recently in conversations with a Marketing Manager
and a Sales Development Manager of two different
OEMs, the validity of this standard came into
question.
question

.2009 Philippi-Hagenbuch, Inc

Body Sizing
Off-Highway Truck Payload is determined by:
Density of material
Body volume

.2009 Philippi-Hagenbuch, Inc

Body Sizing
The SAE Standard does not define an effective
body volume, but does define two (2) different load
ratings:
ti
Struck
Heaped

.2009 Philippi-Hagenbuch, Inc

Body Sizing
SAE Struck Capacity
To measure the struck capacity of an off-highway
t k body
truck b d you close
l off
ff th
the open rear-endd off an off-
ff
highway truck body starting at the rear edge of the
floor plate with a theoretical line drawn upward at a
1:1 slope to the water line or top of the body sides.
(45)
Copyright 2000 Society of Automotive Engineers, Inc.

.2009 Philippi-Hagenbuch, Inc

Boundaries of the struck volume

Planes defined by the intermediate or discharge edges

.2009 Philippi-Hagenbuch, Inc

SAE Struck Capacity

No material can be carried at a

1:1 slope.

.2009 Philippi-Hagenbuch, Inc

Typical Angles of Repose
ANGLES OF REPOSE OF VARIOUS MATERIALS
Angle between horizontal and slope of heaped pile

MATERIAL Ratio Degrees

Coal, Industrial 1.4:1 35
Common earth Dry 2.8:1 20
Moist 2.1:1 25
Wet 2.1:1 25
Gravel g
Round to angular 1 7:1
1.7:1 30
Sand & clay 2.8:1 20

Sand Dry 2.8:1 20

Moist 1.8:1 30
Wet 2.8:1 20
.2009 Philippi-Hagenbuch, Inc Source: an OEM Manufacturers Handbook
Body Sizing

The SAE struck rating

g
is bogus, but what
p rating?
about heaped g

.2009 Philippi-Hagenbuch, Inc

Body Sizing

SAE 2:1 Heap Rating:

3.3.1 Heaped capacity of a dumper or trailer body shall be

the sum of the struck volume and the top volume enclosed
by the four planes at a slope of two horizontal to one vertical
(2:1) extending inward and upward from the mean lines of
the sides and end plates or load-carrying extensions
thereof.
thereof
For bodies with open ends or sides, the 2:1 slope for
p capacity
heaped p y shall start from the top
p of the 1:1 slope
p
which determines struck volume
.2009 Philippi-Hagenbuch, Inc
SAE Standard:

.2009 Philippi-Hagenbuch, Inc

Body Sizing

What about a load with 2 different material slopes?

Whoever heard of the same material having

two different slopes?

.2009 Philippi-Hagenbuch, Inc

 Body Sizing

See 4.4.2 SAE 2:1 Heap

See 4.4.2

See See
4.4.2
4.4.2

Whoever heard of a load looking like the

roof of a house??
.2009 Philippi-Hagenbuch, Inc
Body Sizing

One manufacturer states:

In their spec sheets, SAE Heap overrates the

capacity by 5-6% and is not achievable in practice by:

5 - 6%
.2009 Philippi-Hagenbuch, Inc
Body Sizing

Another manufacturer:

For many years, [we] rated our bodies using a 2:1

fi ld h
field heap which
hi h assumed da22:1
1hheap ffrom allll points
i t
around the body.

.2009 Philippi-Hagenbuch, Inc

Body Sizing

How can you determine a

truck bodys effective load?

Taking the same

truck body, one can
easily arrive at 10
different load ratings.
From 20.7 yd3 to
35 6 yd3
35.6

.2009 Philippi-Hagenbuch, Inc

Body Sizing

How can this bogus rating be overcome??

.2009 Philippi-Hagenbuch, Inc

Body Sizing

Any material dumped makes a cone, or a

conical load
load.

.2009 Philippi-Hagenbuch, Inc

Body Sizing
A conical load in a body

Material naturally flows to a cone in a body.

.2009 Philippi-Hagenbuch, Inc
Body Sizing
Typical Truck Load

.2009 Philippi-Hagenbuch, Inc

Body Sizing

Patent Pending

.2009 Philippi-Hagenbuch, Inc

Body Sizing

What did we find out?

THERE IS NO ONE SINGLE ANGLE OF REPOSE

FOR A LOAD OF MATERIAL

.2009 Philippi-Hagenbuch, Inc

Hauled Material Angles of Repose

Front Rear Side

Location Mine Material Hauled
Angle Angle Angle
Australia Coal Overburden 24 28 34
Australia Coal Overburden 21 31 33
A t li
Australia G ld
Gold W t & Ore
Waste O 26 26 33
Chile Copper Waste & Ore 18 30 32
USA Coal Overburden 24 31 24
USA Copper Waste & Ore 29 31 24
USA Iron Waste & Ore 29 31 33
USA Iron Waste & Ore 29 34 34
.2009 Philippi-Hagenbuch, Inc
Angles of Repose

.2009 Philippi-Hagenbuch, Inc

Body Sizing
When making body choices, know the differences
between:
Profiled Load
2:1 field heap
SAE 2:1 Heap

.2009 Philippi-Hagenbuch, Inc

Loading Factors
Factors Ignored -
Body corner voids
Material loading from a chute forms conical shape
Voids will occur in the four body corners unless
material is spoon-filled into dump body
Loading equipment
With trends towards 2-plus pass loading, little
control exists over how material is placed in truck
body

.2009 Philippi-Hagenbuch, Inc

Loading Factors
Bodies designed for the loading equipment?
Shovel loaded requires wider body
Front End loader requires longer body
Minimizes need for loading to spill point

.2009 Philippi-Hagenbuch, Inc

 CORRECT

5.59%
overloaded
INCORRECT
This diagram shows
how the three load
profiles (Load
P fil d, 2:1
Profiled 21h heap
from all points and
REALLY
13 48%
13.48% WRONG! SAE 2:1 heap) impact
overloaded the center of gravity.

.2009 Philippi-Hagenbuch, Inc

Our experience shows

The SAE 2:1 Heap overrates a truck body

by as little as

7%
to as much as
18%

.2009 Philippi-Hagenbuch, Inc

Dump Clearance
Body design floor configuration
Angle of body floor dump to release material from
truck body
45o floor angle at full dump is usually sufficient

.2009 Philippi-Hagenbuch, Inc

Properly Sized & Balanced Load

.2009 Philippi-Hagenbuch, Inc

How Safety In Numbers Adds Up
Ground clearance is a factor in safe body life and
operation
Proper body weight to load ratio keeps the Center
of Gravity low, and the load distributed correctly on
chassis
Body width assists in loader operators in loading
body safely and correctly each and every load
Wider bodies = less whole body / truck vibration
which is safer for the truck operator
.2009 Philippi-Hagenbuch, Inc
How Safety In Numbers Adds Up
Knowing the density of the material being hauled
lets the body manufacturer accurately design the
b d ffor it
body its iintended
t d d use
Knowing what the actual capacity of the load is,
and profiling the load accurately cuts down on
unneeded steel, and maximizes payload

.2009 Philippi-Hagenbuch, Inc

Presented By:

Josh Swank
Sales Manager
Philippi-Hagenbuch,
Philippi Hagenbuch, Inc.
7424 W. Plank Road
Peoria,, Illinois 61604
(309) 6979200
jjjjswank@philsystems.com
@ y

.2009 Philippi-Hagenbuch, Inc